Methods and Apparatus for Solid Carbonaceous Materials Synthesis Gas Generation

ABSTRACT

Methods and apparatus may permit the generation of consistent output synthesis gas from highly variable input feedstock solids carbonaceous materials. A stoichiometric objectivistic chemic environment may be established to stoichiometrically control carbon content in a solid carbonaceous materials gasifier system. Processing of carbonaceous materials may include dominative pyrolytic decomposition and multiple coil carbonaceous reformation. Dynamically adjustable process determinative parameters may be utilized to refine processing, including process utilization of negatively electrostatically enhanced water species, process utilization of flue gas ( 9 ), and adjustment of process flow rate characteristics. Recycling may be employed for internal reuse of process materials, including recycled negatively electrostatically enhanced water species, recycled flue gas ( 9 ), and recycled contaminants. Synthesis gas generation may involve predetermining a desired synthesis gas for output and creating high yields of such a predetermined desired synthesis gas.

TECHNICAL FIELD

The inventive technology described herein relates to gasifier systemsutilizing solid carbonaceous materials to generate synthesis gases. Morespecifically, such gasifier systems may be configured to utilize one ormore of a variety of process control parameters, perhaps singly or incombinations, to achieve high degrees of efficiency and control in suchsynthesis gas generation. The inventive technology may be particularlysuited to receive a great variety of solid carbonaceous materials asfeedstock for the gasifier system and to generate synthesis gases ofvariable types suitable for a great variety of subsequent applications.

BACKGROUND

Pyrolysis, or controlled heating of feedstock in the absence of oxygen,resulting in thermal decomposition of the feedstock fuel into volatilegases and solid carbon material by-product, was first practiced on acommercial scale in 1812, when a city gas company in London started theproduction of town gas applications.

The first commercial gasifier (updraft type) for continuous gasificationof solid fuels, representing an air-blown process, was installed in 1839producing what is known as “producer gas” combustion type gasifiers.They were further developed for different input fuel feedstocks and werein widespread use in specific industrial power and heat applicationsthroughout the late 1800's and into the mid-1920's, when petroleumfueled systems gradually took over the producer gas fuel markets.

Between 1920 and 1940, small and compact gasifier systems for automotiveapplications were developed in Europe. During the Second World War,perhaps tens of thousands of these combustion type gasifiers were usedin Europe and across other scattered market applications. Shortly afterthe War most gasifiers were decommissioned because of widespreadavailability of commercial gasoline and diesel fuels.

Gasification emphasis again came to the forefront due to the energycrisis of the 1970's. Gasifier technology was perceived as a relativelycheap alternative for small-scale industrial and utility powergeneration, especially when sufficient sustainable biomass resourceswere available. By the beginning of the 1980's nearly a dozen (mainlyEuropean) manufacturers were offering small-scale wood and charcoalfired “steam generation” power plants.

In Western countries, coal gasification systems began to experienceexpanded interest during the 1980's as an alternative for theutilization of natural gas and oil as the base energy resource.Technology development perhaps mainly evolved as fluidized bedgasification systems for coal, but also for the gasification of biomass.Over the last 15 years, there may have been much development ofgasification systems as directed toward the production of electricityand generation of heat in advanced gas turbine based co-generationunits.

Gasification of biomass perhaps can appear deceptively simple inprinciple and many types of gasifiers have been developed. Theproduction of combustible syn-gas from biomass input fuel may haveattractive potential benefits perhaps such as ridding the environment ofnoxious waste disposal problems, possible ease of handling, and perhapsproviding alternative energy production with possibly the release of lowlevels of atmospheric environmental contaminants. Further, cheapelectricity generation and the application of the produced syn-gas as aneconomical energy source for the manufacture of liquid fuels may alsooften make gasification very appealing.

However, the biomass input feedstock which is used in gasifiers maychallenge perceptions of uncomplicated design simplicity since thefeedstock material may represent varying chemical characteristic andphysical properties, perhaps as inherent and unique to each individualbiomass feedstock material. The chemical reactions involved ingasification, relative to processing the different varieties ofavailable biomass materials, may involve many different reactants andmany possible reaction pathways. The reaction rates are often relativelyhigh; all these variable factors may contribute to the perhaps verycomplex and complicating nature of gasification processes. All too oftenuncontrollable variables may exist that may make gasifiers hard to massbalance control and perhaps to operate satisfactorily within knownpreventive maintenance procedures, steady-state output constants, andmanageable environmental control compliance areas.

Numerous U.S. patents have been issued relating to alternative orrenewable energy technology descriptions involving gasification orsyn-gas technologies. The present inventive technology perhaps mayovercome many of the operational disadvantages associated with andperhaps commonplace to current and commercially viable processesinvolving existing gasification systems. The various types of availablemarket updraft, downdraft, air-blown, fixed bed, fluidized bed,circulating fluidized bed, pulsed-bed, encapsulated entrained flow, andother gasification systems may often have one or more seriousdisadvantages that perhaps may be overcome by the present inventivetechnology.

In conventional gasification systems, disadvantages often may exist thatmay create problems in perhaps a variety of areas, including but notlimited to areas such as: process control stability related to inputfeedstock changes, steady state loading, blockage and overall systemthroughput limitations; slagging potential and challenges; scale-upsizing challenges; moisture limitations; system gas and internal vaporleak challenges; carry-through impurities and contamination challenges,system plugging challenges (such as with excess char, tars or phenols);problems with generated hydrocarbon volatiles and other corrosive sulfurvapor carry-through contaminants being released into produced synthesisgas; decreased BTU energy values in final produced synthesis gas (suchas due to excess CO₂, N₂, or particulate contamination); and the like.

For example, conventional gasification systems may use horizontal-planescrew for moving feedstock material, at controlled throughput feedrates, into other competitive gasification thermal reactor systems andalso for simultaneously utilizing the enclosed auger pipe housing (oftenusing more than one auger system in a one-to-the-other configuration) asan enclosed temperature stage initial devolatilization zone. However,these combined double-duty auger system designs may often be plaguedwith numerous and sporadic mechanical, unpredictable and uncontrollableprocess (negative) variables. Such variables can be considered ascentering around problems associated with input feed solids that canoften rope/lock disproportionally together or that can otherwise causeplugging or binding of the auger shaft, helical flights and/or blind theauger close tolerance receiver pipe cylinder openings. This can in-turnwarp the auger drive shaft into a bent and/or an ellipticalconfiguration. Auger shaft warpage can cause a high side rotationalinternal friction wear and can rapidly create stress cracks in anauger-pipe cylinder housing unit. This can cause constant processpressure variation and can cause vapor leaks. Excess friction drag canalso break shafts. Further, intermittent carbonaceous material bulk jamscan occur whereby the throughput devolatilization reactivity can beeither lost or slowed. Feedstock decomposition and devolatilizationreactions can also begin to occur at the surface of the plug/jam,therefore releasing, and perhaps slowly devolatilizing, char solids,phenols, tars, surfactants and other surface chemical hydrocarbonconstituents that can further liquefy and wax or seal the outerbulk-mass surface of the plug materials into an even tighter and morecementaceous plug. Incoming feedstock “plug mass” can quickly fill intoand blind the relatively small cross-section diameter surface areanarrower openings within typical auger screw pipe cylinder housings.This can also begin to close off the auger screw conduit that alsoserves as an initial devolatilization chamber.

The foregoing problems regarding conventional technologies may representa long-felt need for an effective solution to the same. Whileimplementing elements may have been available, actual attempts to meetthis need to the degree now accomplished may have been lacking to somedegree. This may have been due to a failure of those having ordinaryskill in the art to fully appreciate or understand the nature of theproblems and challenges involved. As a result of this lack ofunderstanding, attempts to meet these long-felt needs may have failed toeffectively solve one or more of the problems or challenges hereidentified. These attempts may even have led away from the technicaldirections taken by the present inventive technology and may even resultin the achievements of the present inventive technology being consideredto some degree an unexpected result of the approach taken by some in thefield.

SUMMARY DISCLOSURE OF INVENTION

The inventive technology relates to methods and apparatus for solidcarbonaceous materials synthesis gas generation and embodiments mayinclude the following features: techniques for affirmativelyestablishing a stoichiometric objectivistic chemic environment in asolid carbonaceous materials gasifier system; techniques forstoichiometrically controlling carbon content in a solid carbonaceousmaterials gasifier system; techniques for multiple coil carbonaceousreformation in a solid carbonaceous materials gasifier system;techniques for utilizing negatively electrostatically enhanced waterspecies in a solid carbonaceous materials gasifier system; techniquesfor recycling materials within a solid carbonaceous materials gasifiersystem; techniques for dominative pyrolytic decomposition ofcarbonaceous materials within a solid carbonaceous materials gasifiersystem; techniques for solubilizing contaminants in a solid carbonaceousmaterials gasifier system; techniques for recycling solubilizedcontaminants within a solid carbonaceous materials gasifier system;techniques for creating a high energy content select product gas from asolid carbonaceous materials gasifier system; techniques for dynamicallyadjusting process determinative parameters within a solid carbonaceousmaterials gasifier system; techniques for predetermining a desiredselect product gas for output from a solid carbonaceous materialsgasifier system; techniques for high yield output of a select productgas from a solid carbonaceous materials gasifier system; techniques formagnetic isolation of feedstock solids carbonaceous materialsconstituent components in a solid carbonaceous materials gasifiersystem; techniques for displacing oxygen from feedstock solidscarbonaceous materials in a solid carbonaceous materials gasifiersystem; techniques for adjusting process flow rates within a solidcarbonaceous materials gasifier system; and techniques for flue gasand/or product gas generation and recycling within a solid carbonaceousmaterials gasifier system. Accordingly, the objects of the methods andapparatus for solid carbonaceous materials synthesis gas generationdescribed herein address each of the foregoing in a practical manner.Naturally, further objects of the inventive technology will becomeapparent from the description and drawings below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a conceptual view of a gasifier process flow path withdelimited functional areas in one embodiment.

FIG. 2 is a conceptual view of a gasifier process flow path withoutdelimited functional areas in one embodiment.

FIG. 3 is a front perspective view of a solid carbonaceous materialsgasifier system in one embodiment.

FIG. 4 is rear perspective view of a solid carbonaceous materialsgasifier system in one embodiment.

FIG. 5 is a sectional cutaway view of a multiple coil carbonaceousreformation vessel in one embodiment.

FIG. 6 is a perspective view of a multiple coil carbonaceous reformationvessel in one embodiment.

FIG. 7 is a perspective view of a multiple coil carbonaceous reformationvessel in one embodiment.

FIG. 8 is a side cutaway view of a venturi injector in one embodiment.

FIG. 9 is a cross section view of a venturi injector in one embodiment.

FIG. 10 is a diagrammatic view of a negatively electrostaticallyenhanced water species generation unit in one embodiment.

FIG. 11 is a diagrammatic view of a select product gas componentsscrubber in one embodiment.

FIG. 12 is a conceptual view of a pretreatment area of a solidcarbonaceous materials gasifier system in one embodiment.

FIG. 13 is a conceptual view of a pyrolytic decomposition area of asolid carbonaceous materials gasifier system in one embodiment.

FIG. 14 is a conceptual view of a carbonaceous materials reformationarea of a solid carbonaceous materials gasifier system in oneembodiment.

FIG. 15 is a conceptual view of an ash removal area of a solidcarbonaceous materials gasifier system in one embodiment.

FIG. 16 is a conceptual view of a scrubber area of a solid carbonaceousmaterials gasifier system in one embodiment.

FIG. 17 is a conceptual view of an auxiliary-treatment area of a solidcarbonaceous materials gasifier system in one embodiment.

FIG. 18 is a cross section view of a “pod” embodiment of the presentinventive technology.

FIG. 19 is a perspective view of a trailerable embodiment of the presentinventive technology.

FIG. 20 is a perspective view of a portion of a “pod” embodiment of thepresent inventive technology.

FIG. 21 is a cross-section view of a reactor portion of a “pod”embodiment of the present inventive technology.

FIG. 22 is a perspective view of a lower portion of a “pod” embodimentof the present inventive technology.

MODES FOR CARRYING OUT THE INVENTION

The present inventive technology includes a variety of aspects, whichmay be combined in different ways. The following descriptions areprovided to list elements and describe some of the embodiments of thepresent inventive technology. These elements are listed with initialembodiments, however it should be understood that they may be combinedin any manner and in any number to create additional embodiments. Thevariously described examples and preferred embodiments should not beconstrued to limit the present inventive technology to only theexplicitly described systems, techniques, and applications. Further,this description should be understood to support and encompassdescriptions and claims of all the various embodiments, systems,techniques, methods, devices, and applications with any number of thedisclosed elements, with each element alone, and also with any and allvarious permutations and combinations of all elements in this or anysubsequent application.

A solid carbonaceous materials gasifier system in various embodimentsperhaps may be configured to modular sections. Embodiments may involve asystem having functional areas (FIGS. 1; 4) perhaps such as:

-   -   a pretreatment area (74), perhaps to include bulk handling of        input feedstock solid carbonaceous material, displacement at        least some oxygen content from the feedstock solid carbonaceous        material, and perhaps other preparation handling for subsequent        processing of the feedstock solid carbonaceous material;    -   a pyrolytic decomposition area (75), perhaps to include varying        a retention time of feedstock solid carbonaceous material in a        temperature varied environment, as in perhaps a pyrolysis        chamber;    -   a carbonaceous materials reformation area (77), perhaps to        include carbonaceous reformation of pyrolytically decomposed        carbonaceous materials, such as in a multiple coil reformation        vessel or perhaps even in a helically nested configuration of        reformation coils in a multiple coil reformation vessel;    -   an ash removal area (78), perhaps to include ash removal such as        by downdraft cool-down and pulse-evacuation containment;    -   a scrubber area (79), perhaps to include removal of contaminants        from a generated select product gas, such as by combined chill        and spray of a negative electrostatically enhanced water species        and even polarized media polish filtration;    -   an auxiliary treatment area (76), perhaps to include select        product gas preparation for gasifier embodiment combustion        heating, such as with oxygen enrichment and reduction of        nitrogen content, perhaps utilizing an air separation unit.

Of course, these areas merely exemplify one possible modularconfiguration for a solid carbonaceous materials gasifier system toillustrate the concept of modularity in perhaps one embodiment, andshould not be regarded as limiting the possible modular configurationsof such a gasifier system, the distribution of various gasificationfunctions within modular sections of a gasifier system, or indeed evento limit the inventive technology to modular embodiments, consistentwith the inventive principles discussed herein.

The inventive technology may involve processes for carbon conversionthat perhaps may be categorized as gasification. Carbon conversion mayinvolve the conversion of carbon content in a feedstock solidscarbonaceous material, perhaps including a majority or possibly evensubstantially all of such carbon content, into select product gascomponents or even a select product gas. In embodiments, such processesmay include thermal processes, perhaps including elevated temperaturesin reducing conditions or with little or no free oxygen present, toproduce a select product gas, such as a permanent and combustiblesynthesis gas. Such a select product gas often may include predominantlyCO and H₂, with some CH₄ volume output, though the process controlparameters may allow significant control over the make-up of a producedselect product gas in particular applications. The process also mayinvolve minor by-products of various types, perhaps such as char ash,condensable inorganics and organics, or trace hydrocarbons.

In some embodiments, a solid carbonaceous materials gasifier system maybe initially started with an auxiliary fuel, such as an external sourceof propane, as may be supplied to a gasifier system process enclosure,for example such as to a box furnace enclosure (26) (FIGS. 1; 2; 13) ata combustive burner (14) (FIGS. 1; 2). This may be used, for example,perhaps until the reformation coils (19) (FIGS. 1; 2; 3; 4) of amultiple coil reformation vessel reach a suitable operationaltemperature, for example perhaps about 1600° F. to 1800° F. In someembodiments, this may take approximately 24 hours. At this point someembodiments may be capable of producing a select product gas whereby afractional portion may be returned to the combustive burner to sustaincombustion and maintain a desired process operational temperature. Inthis manner, the system perhaps may become self-sustaining and auxiliaryfuel support may be shut off, perhaps with input delivery of feedstocksolids carbonaceous materials for processing to be started or continuedinto the gasifier system.

A solid carbonaceous materials gasifier system in various embodimentsmay include a gasifier process flow path originating at a feedstocksolids carbonaceous materials input and routed through the solidcarbonaceous materials process gasifier system. A process flow path mayprovide a path by which solid carbonaceous materials input into thegasifier system may be routed to various processing areas of thegasifier system, perhaps ultimately for output of a select product gasat a terminus of the gasifier process flow path. Moreover, such agasifier system perhaps may be characterized as capable of receivingsolid carbonaceous materials at the input of the gasifier process flowpath, which carbonaceous materials may be solid in nature, perhaps asdistinguished from fluidized bed and updraft or downdraft gasifierswhich often utilize liquid feedstocks, slurried feedstocks, or otherfeedstock having substantially non-solidified compositions. For example,such solid carbonaceous material in some embodiments may include solidcarbonaceous particles milled to a size appropriate for throughputthrough the gasifier system's process flow path, such as perhaps to lessthan about 2 cubic inches in particle size. Moreover, the dynamicadjustability of various process control parameters may permit thegasifier system to accept a great variety of solid carbonaceousmaterials for input, with the dynamic adjustability of the gasifiersystem compensating for variations in the input make-up to permitconsistent output of desired select product gas. For example, solidcarbonaceous materials suitable for input may include, but of course arenot limited to, varied carbon content, varied oxygen content, variedhydrogen content, varied water content, varied particle sizes, variedhardness, varied density, and the like, perhaps such as including variedwood waste content, varied municipal solid waste content, varied garbagecontent, varied sewage solids content, varied manure content, variedbiomass content, varied rubber content, varied coal content, variedpetroleum coke content, varied food waste content, varied agriculturalwaste content, and the like.

A solid carbonaceous materials gasifier system in various embodimentsmay be configured to process feedstock solids carbonaceous materials ina variety of manners. Processing may involve perhaps simply treating acarbonaceous material in some capacity. For example, processing invarious embodiments may include pretreating a feedstock solidscarbonaceous material within a pretreatment area, pyrolyticallydecomposing in a pyrolysis chamber, carbonaceously reforming in amultiple coil carbonaceous reformation vessel, preliminarilycarbonaceously reforming in a preliminary carbonaceous reformation coil,secondarily carbonaceously reforming in a secondary carbonaceousreformation coil, tertiarily carbonaceously reforming in a tertiarycarbonaceous reformation coil, vaporizing a carbonaceous materialincluding perhaps vaporizing hydrocarbons or perhaps vaporizing selectproduct gas components, processing with a negatively electrostaticallyenhanced water species, processing with negatively electrostaticallyenhanced steam, processing with a flue gas, processing with apressurized flue gas, processing with a preheated flue gas, processingwith a scrubber recycled tar, processing with a scrubber recycledphenol, processing with a scrubber recycled solid, processing with aselect product gas, processing with a wet select product gas, processingwith a dry select product gas, processing with a recycled select productgas, or other appropriate steps of treating carbonaceous materialsappropriate for gasification processes. Moreover, embodiments mayinclude multiple processing steps, which may be related as steps ofinitial processing, subsequent processing, and the like. Of course, suchsteps of processing may be accomplished by an appropriate processor, forexample a pretreatment area processor, a pyrolysis chamber, a multiplecoil carbonaceous reformation vessel, a preliminary carbonaceousreformation coil of a multiple coil carbonaceous reformation vessel, asecondary carbonaceous reformation coil of a multiple coil carbonaceousreformation vessel, a tertiary carbonaceous reformation coil of amultiple coil carbonaceous reformation vessel, and the like.

A feedstock solids carbonaceous materials input in some embodiments mayinclude a walking floor or other raw feedstock holding bin (1) (FIGS. 1;2; 12), perhaps with a continuous volume of input feedstock solidscarbonaceous material that has been previously milled or shredded to aninput particle size not to exceed as desired. Further, in embodiments,an inventory storage volume may be selected, for example perhaps a fiveday inventory storage volume, to ensure a consistent supply of feedstockcarbonaceous materials for input. In embodiments, gasifier systemexhaust flue gas (9) (FIGS. 1; 2; 12), produced for example perhaps bycombustive burners, may be directed to a compressor, such as a hightemperature delivery compressor (8) (FIGS. 1; 2; 12), whereby the fluegas temperature may be reduced from a high temperature, perhapsapproximately 700° F., to a lower temperature. This may occur via anin-line heat exchanger or the like, not shown. In embodiments,temperature reduction may be down to about 300° F. Further, thecompressor may also pressure regulate small volume and may alsointermittently inject hot flue gas into a holding bin to additionallydry out moisture within the feedstock solids carbonaceous material, ifrequired. A suitable feedstock delivery system, such as a variable speedhorizontal metering screw (not shown), may be used to deliver acontrolled rate volume feed of feedstock solids carbonaceous material toa variable speed inclined conveyor (2) (FIGS. 1; 2; 3; 4; 12) or thelike.

A pressure system in some embodiments may be joined to a gasifierprocess flow path to pressurize the feedstock solids carbonaceousmaterial as appropriate, for example perhaps by configuring the variablespeed inclined conveyor to be sealed, perhaps such as in apressure-tight unit cylinder. Such a pressure system also may include aflue gas delivery compressor to perhaps also pressure regulate a smallbut continuous volume delivery of hot flue gas into a conveyor unit,perhaps sealed cylinder, with perhaps an about 40 psi pressure beingmaintained throughout the conveyor feed cylinder. This may be fed intoan inlet feed plenum assembly (6) (FIGS. 1; 2; 3; 12). The pressuresystem further may involve a conveyor unit cylinder pressure (perhapsflanged) sealed to an inlet plenum assembly, and the conveyor drivemotor perhaps may be mounted outside the conveyor pressure unitcylinder. Further, a motor drive shaft may also be pressure sealed aspart of a pressure system perhaps through the wall of a conveyor housingcylinder. Flue gas may be further compressed and pressure regulated andinjected at the top of an inlet, perhaps airtight, plenum. This mayoccur such as at injection position (3) (FIGS. 1; 2; 12). Location andamount may be selected to ensure that a desired continuous pre-heattemperature, such as approximately 300° F. and 40 psi positive pressure,is maintained in the inlet plenum chamber.

In addition to the benefit of hot flue gas drying out excess feedstockmoisture, hot flue gas may be used to displace and starve excess air outof the input feedstock materials. Such use of hot flue gas may beemployed as part of an oxygen displacement system, which may represent ameaningful process control variable to limit air content, includingperhaps oxygen levels, in the inlet plenum feed assembly. Such an oxygendisplacement system may be employed gravimetrically, for example perhapsby injecting flue gas at the bottom of an incline, perhaps via anincline base input, through which a feedstock solids carbonaceousmaterial may be moved and releasing oxygen content from the top of theincline, for example perhaps via an incline apex output. In some processconfigurations hot product gas may be substitute added, instead ofutilizing flue gas, to achieve the same drying and displacement benefitsand add more carbon element return. In some embodiments, such an inclinemay be a variable speed inclined conveyor (2) (FIGS. 1; 2; 3; 4; 12) orthe like. Gravimetric displacement may occur as the injected flue gasrises gravimetrically through the incline, perhaps physically displacingair content and oxygen content along the way. Release of the displacedair or oxygen content may be affected through use of a suitable port,valve, outlet, or the like, at the top of the incline. Moreover, whileinjected flue gas may suffice for oxygen displacement, it may beappreciated that any suitable substance may be injected consistent withthe gravimetric principles herein described, including for example usingflue gas, using pressurized flue gas, using preheated flue gas, usingrecycled flue gas, using select product gas, using wet select productgas, using dry select product gas, using recycled select product gas,and the like. Of course, temperature and pressure characteristics ofthese injected substances may be selected as appropriate to achieveoxygen displacement, including for example pressurizing to at least 40psi and preheating to at least 300 degrees Fahrenheit.

Further, the flue gas may consist of large concentrations of CO whichmay assist in the conversion of volatile gases to release free carbon.Periodic small volumes of plenum flue gas may also be auto-vented as asafety relief perhaps such as through an exhaust filter (5) (FIGS. 1; 2;12) and a pressure relief/control valve (71) (FIGS. 1; 2; 13) which maybe configured at the top of a plenum exhaust bleed outlet (4) (FIGS. 1;2; 12). This may also be directed to an external flare system.

A gasifier flow path may be routed through one or more suitable airlockcomponents to maintain pressure in a pressure system, for example arotary type airlock material feed-through valve (not shown). Suchairlock components may be configured to ensure that a desired pressure,for example perhaps a constant 40 psi pressure, can be held among thepressurized components of the system, for example perhaps at the plenumdelivery system. Such maintained pressure also may prevent the back-feedof materials from subsequent processing areas of the gasifier system. Inaddition, by maintaining a perhaps 40 psi or so positive plenumpressure, the downward injection of feedstock solids carbonaceousmaterials into subsequent processing areas may be pressure assisted. Inembodiments, the feedstock solids carbonaceous materials may transfer bygravity through a suitable airlock component, for example perhapsthrough wide throat airlock valves. In this arrangement, one valve maysequence into an open position while the other valve remains in a closedposition, thereby allowing a volume of feedstock material to be retainedin a holding chamber between the two valves. In this, or other manners,when the lower valve opens, the feedstock material may drop into aconnecting conduit, perhaps through a box furnace enclosure (26) (FIGS.1; 2) and into a subsequent processing areas of the gasifier system(FIGS. 1; 2).

Of course, a pressure system through which a gasifier process flow pathis routed should not be construed as limited merely to the foregoingexamples described herein. Rather, a pressure system perhaps simply mayinvolve maintaining one or more areas within a solid carbonaceousmaterials gasifier system at a different pressure than that outside ofthe solid carbonaceous materials gasifier system. Such pressuremaintenance may be accomplished in any suitable manner consistent withthe principles described herein, for example perhaps through the use ofan airlock, a double airlock, an injector that injects a pressurizedsubstance such as a pressurized flue gas or pressurized select productgas, or perhaps even an inductor configured to maintain a pressure.Moreover, a pressure system may be applied to any gasifier systemenclosures for which pressurization may be required, such as perhaps apretreatment environment enclosure, a pyrolysis chamber enclosure, amultiple coil carbonaceous reformation vessel enclosure, any or allparts of a gasifier process flow path routed through a solidcarbonaceous materials gasifier system, and the like. In someembodiments, a pressure system may be sealed, for example as to preventcommunication between the pressurized environment and an unpressurizedenvironment or perhaps to seal a feedstock solids carbonaceous materialwithin the solid carbonaceous materials gasifier system.

Various embodiments may involve joining a heater system to a gasifierprocess flow path. Joining may be understood to involve perhaps simplybrining two elements into some degree of mutual relation, for example, aheater system joined to a gasifier process flow path simply may permitthe heater system to heat at least some of the gasifier process flowpath. Heating in this manner may be effected in any suitable manner, forexample perhaps by a combustive burner, an electric heater or the like.In various embodiments, a heater system may be configured to supply heatappropriate for a particular processing stage. In this manner, a heatersystem in various embodiments may include pyrolysis temperature heatersystem, a carbonaceous reformation temperature heater system, a variabletemperature zone heater system, a heater system configured to establisha temperature from 125° F. to 135° F., a heater system configured toestablish a temperature from 135° F. to 300° F., a heater systemconfigured to establish a temperature from 300° F. to 1,000° F., aheater system configured to establish a temperature from 1,000° F. to1,640° F., and a heater system configured to establish a temperaturefrom 1,640° F. to 1,850° F.

In various embodiments, a gasifier process flow path may be routedthrough a temperature varied environment. A temperature variedenvironment may include a contiguous portion of a gasifier process flowpath heated to varied temperatures, as for example by a variabletemperature zone heater system. Some embodiments may use a gravity dropflow of feedstock material such as from the bottom of airlock valve (7)(FIGS. 1; 2; 3; 4; 12) and through the wall of a box furnace enclosure(26) (FIGS. 1; 2; 13). This perhaps may be arranged directly into atemperature varied environment, perhaps where one or more dynamicallyadjustable process flow parameters may be utilized to process thefeedstock solids carbonaceous material. Overall operational temperaturesuch as within a temperature varied environment may be regulated so thatan inlet conduit entering from a previous processing area may provideincoming feedstock solids carbonaceous materials at an elevatedtemperature, perhaps such as at approximately 250° F. to 300° F., andperhaps as dependant upon any of various suitable dynamically adjustableprocess determinative parameters, such as the volume of a negativelyelectrostatically enhanced water species or the temperature of aninjected flue gas. A temperature gradient may be established within thetemperature varied environment perhaps from about 300° F. at an inputarea and reaching about 900° F. to 1000° F. toward an output area. Ofcourse, any suitable heater system capable of variable heat output maybe used to achieve such variable temperature zones. In some embodiments,for example, a series of electric heaters, combustive burners, or thelike may be configured to produce a temperature varied environment.

A temperature varied environment in various embodiments may include aliquefaction zone. A liquefaction zone may be a temperature zone of avaried temperature environment in which feedstock solids carbonaceousmaterials may tend to liquefy, for example such as by being heated totheir liquefaction temperature. Embodiments may include a plurality ofmovement guides in a temperature varied environment, perhaps temperaturevariable movement guides capable of being heated to varied temperaturesas a result of being moved through said temperature varied environment,perhaps including trans-liquefaction movement guides disposed throughthe temperature varied environment that may engage a feedstock solidscarbonaceous material for transport through the temperature variedenvironment and liquefaction zone. Such movement through theliquefaction zone may include receiving a feedstock solids carbonaceousmaterial at a pre-liquefaction temperature zone of the temperaturevaried environment, which may perhaps be a cooler temperature thanrequired to liquefy the feedstock solids carbonaceous material, movingthe feedstock solids carbonaceous material through the liquefactionzone, at which point the feedstock solids carbonaceous material mayliquefy, and moving the liquefied feedstock solids carbonaceous materialinto a post-liquefaction temperature zone, which may perhaps be a hottertemperature than the liquefaction temperature of the feedstock solidscarbonaceous material.

In some embodiments, a plurality of trans-liquefaction movement guidesmay be joined to a temperature varied cyclical return. Such atemperature varied cyclical return may permit the trans-liquefactionmovement guides to move through the temperature varied environment on acyclical path. A trans-liquefaction movement guide undergoing suchcyclical motion, for example, may begin within one temperature zone ofthe temperature varied environment, move through one or more othertemperature zones of the temperature varied environment, and be returnedto its original starting position within the first temperature zone ofthe temperature varied environment, where the cycle may be repeated. Ofcourse, any of a variety of appropriate devices may accomplish suchcycling. In some embodiments, for example, a temperature varied cyclicalreturn may include an endless loop conveyor system, perhaps such as atrack feeder (10) (FIGS. 1; 2; 3; 4; 13). Embodiments also may includevarying the speed at which a temperature varied cyclical return isoperated, perhaps to vary a retention time at which feedstock solidcarbonaceous materials engaged by a plurality of trans-liquefactionmovement guides may be retained within a temperature varied environment.In this manner, a track feeder (10) (FIGS. 1; 2; 3; 4; 13) may beprovided with a variable return cycle.

In some embodiments, movement guides may be translatable movementguides. Configuring movement guides to be translatable may involvemoving a feedstock solids carbonaceous material engaged to the movementguide by physically translating the movement guide itself. For example,where movement guides in embodiments may be joined to a temperaturevaried cyclical return, the cyclical motion of the return may act tophysically translate the position of the movement guides, as perhapsthrough the cyclical motion of the return. Moreover, such a translatablenature of movement guides may be compared to non-translating motionsystems, for example perhaps rotating screw systems, wherein theposition of the screw itself may not translate and motion may beimparted simply by the rotation of the screw. In some embodiments, thetranslatable nature of the movement guides may assist in preventingbinding of the movement guides by liquefied feedstock solidscarbonaceous materials, perhaps in as much as translating the positionof the movement guides may serve to translationally push liquefyingfeedstock into a higher temperature zone, and even possibly bycyclically varying the temperature of the movement guides themselves toavoid holding them at a liquefaction temperature.

Cycling movement guides in a temperature varied environment further mayinclude automatically periodically clearing the movement guides offeedstock solids carbonaceous materials that may have liquefied whenmoved through a liquefaction zone. For example, cycling may involvecontinuously varying the temperature of the movement guides, perhapsincluding cyclically raising and lowering the temperature of themovement guides as they are cycled through a varied temperature regime.Such temperature change of the movement guides may be alternatelythrough a pre-liquefaction temperature and a post-liquefactiontemperature, avoiding holding of the movement guides at a liquefactiontemperature, and in this manner it may be seen that liquefied feedstocksolids carbonaceous material to which individual movement guides areengaged may be vaporized as the movement guides cycle through theirpost-liquefaction temperatures. Accordingly, the movement guides may beautomatically periodically cleared as a result of such cycling, andbinding of the movement guides may be avoided in as much as theliquefied dry solids carbonaceous feedstock may be systematicallyvaporized. In this manner, the movement guides may be considered asconfigured to avoid a sustained liquefaction temperature, configured forcyclical elevation and reduction in temperature, configured for cyclicalliquefaction and vaporization of feedstock solids carbonaceous material,and may even be considered to be binding resistant movement guides.

A track feeder and plurality of trans-liquefaction movement guides insome embodiments may be configured to include a track-heat-scraperplate. For example, in some embodiments, along the bottom longitudinalcenterline underside of a track heat-scraper plate (not shown) may belocated a parallel row of progressive electric heaters (11) (FIGS. 1; 2;13) that may even sequentially control a temperature gradient.Similarly, in some embodiments a select product gas burner manifold maybe used as a heating source and perhaps may be located external andadjacent to the track feeder embodiment. A scraper wear plate may beperiodically replaced as required and may even be fabricated and castfrom hardened high temperature metallic material. A counter-clockwiserotation of a feeder track may be used to move feedstock solidscarbonaceous material to the bottom underside of the track feeder.

Moreover, in some embodiments, such varied temperatures may includepyrolysis temperatures suitable to pyrolytically decompose at least someof a feedstock solids carbonaceous material routed through thetemperature varied environment along a gasifier process flow path.Pyrolysis may involve heating the feedstock solids carbonaceous materialin the absence of reactively significant amounts of oxygen to inducedecomposition of the feedstock solids carbonaceous material, as perhapsby consequential thermal reactions, chemical reactions, andvolatilization reactions. The absence of such reactively significantamounts of oxygen perhaps need not require the total absence of oxygen(although this condition certainly may be included), but rather perhapsmay include merely an amount of oxygen that produces merelyinsubstantial or perhaps even nonexistent combustion when said feedstocksolids carbonaceous material is subjected to the temperature variedenvironment. In various embodiments, pyrolytically decomposing mayinvolve vaporizing a carbonaceous material, for example perhapsvaporizing hydrocarbons or perhaps vaporizing select product gascomponents. Further, in some embodiments, portions of a temperaturevaried environment in which pyrolytic decomposition may occuraccordingly may be considered to include a pyrolysis chamber.

In some embodiments, pyrolytically decomposing a feedstock solidscarbonaceous material in a temperature varied environment may includedominatively pyrolytically decomposing the feedstock solids carbonaceousmaterial. Such dominative pyrolysis may involve pyrolyzing to a highdegree, perhaps by subjecting the feedstock solids carbonaceous materialto prolonged pyrolyzing conditions. For example, embodiments may includeretaining a feedstock solids carbonaceous material within a pyrolysischamber of a temperature varied environment for at least 2 minutes, atleast 3 minutes, at least 4 minutes, at least 5 minutes, at least 6minutes, at least 7 minutes, at least 8 minutes, at least 9 minutes, atleast 10 minutes, at least 11 minutes, at least 12 minutes, at least 13minutes, at least 14 minutes, at least 15 minutes, at least 16 minutes,at least 17 minutes, at least 18 minutes, at least 19 minutes, or atleast 20 minutes, for example perhaps by varying the speed of atemperature varied cyclical return and a plurality of movement guidesjoined to the temperature varied cyclical return. Such retention timesperhaps may be substantially longer than conventional pyrolysis times,and perhaps may be achievable by minimizing or perhaps even eliminatingbinding caused by liquefaction that perhaps may plague conventionalpyrolysis systems.

Moreover, pyrolysis or even dominative pyrolysis may be facilitated invarious embodiments by maximizing the surface area of a track feeder toincrease the surface area contact of a feedstock solids carbonaceousmaterial to the pyrolysis conditions of a pyrolysis chamber. Forexample, embodiments may include maximizing the surface area of a trackfeeder (10) (FIGS. 1; 2; 3; 4; 13), for example including perhapsdimensioning the track feeder to at least 24 inches in width, to atleast 30 inches in width, to at least 36 inches in width, to at least 42inches in width, to at least 48 inches in width, to at least 54 inchesin width, to at least 60 inches in width, to at least 66 inches inwidth, to at least 72 inches in width, to at least 3 feet in length, toat least 6 feet in length, to at least 9 feet in length, to at least 12feet in length, to at least 15 feet in length, to at least 18 feet inlength, and to at least 21 feet in length. Such dimensions may beperhaps at ten to twenty times greater surface area exposure than aconventional 3 or 4 stage auger feed pyrolysis system design, and may bewithout the binding or plugging probabilities mentioned earlier.

A track feeder in various embodiments may represent an integratedprocess control module, perhaps with sequenced computer automation.Process flow embodiments may be monitored to provide an adjustable timeperiod to extend or shorten pyrolytic decomposition times for throughputfeedstock solids carbonaceous material to undergo perhaps completereaction contact with heat, flue gas CO, negatively electrostaticallyenhanced water species, and the like. A track feeder system design invarious embodiments may be sized to automatically process perhaps about50 tons/day and up to 500 tons/day of input feedstock solidscarbonaceous materials. Of course, multiple track feeders, perhapsrouted through multiple temperature varied environments perhapsincluding pyrolysis chambers, may be utilized in some embodiments toincrease total feedstock solids carbonaceous materials throughput. Trackfeeder maximized surface areas, adjustable temperatures, progressivetime controls, and track speed control variables may be included inembodiments such as to allow extended pyrolysis time or the like and toprovide a capability to near completely pyrolytically decompose thefeedstock solid carbonaceous material, including perhaps tars andphenolic chemistry fractions. In some embodiments, small volumeadditions of calcined dolomite also may be added, for example at apretreatment area, such to speed up and catalyze the sulfurs or tars andphenols initial cracking process that may occur in the pyrolysischamber. Track feeder operational up-time may even approach 100%, exceptperhaps for short 2-3 day periods of monthly preventive maintenance. Thecomponents of a track feeder, such as chains, sprockets, and driveshafts, perhaps may be manufactured from high temperature Inconel® alloymetal stock or the like, or other alternate and appropriate metallicmaterials, and in addition, components such as track flights and bottomtrack scraper wear and heater plates (not shown) may be custom cast withhigh temperature metallurgy or the like. Track feeder drive bearings maybe standard nuclear industry high temperature sealed units, perhaps withan outboard variable speed motor drive unit that may provide a trackrotational movement selection of one to five revolutions per minute. Anadditional auto-vent safety-relief pressure control and relief valve(71) (FIGS. 1; 2; 13; 14) may be installed and perhaps even centeredthrough the top of a box furnace enclosure (26) (FIGS. 1; 2; 13). Ofcourse, the use of a temperature varied cyclical return as describedherein may preclude the need for any type of auger screw or perhaps evenany screw type movement system through a pyrolysis chamber of atemperature varied environment as described herein.

Various embodiments further may include a magnetic materials removalsystem (12) (FIGS. 1; 2) through which a gasifier process flow path isrouted, perhaps to magnetically isolate at least one constituentcomponent of a feedstock solids carbonaceous material. Such a magneticmaterials removal system may use a magnet to magnetically attractmetallic constituent components of a feedstock solids carbonaceousmaterial. Where a nonmetallic constituent component is desired to beremoved, embodiments perhaps may still achieve removal of suchnonmetallic constituent components perhaps by creating a metal oxide ofthe nonmetallic constituent components, perhaps in a metals oxidationarea, and magnetically attracting the created metal oxide. In someembodiments, oxidation may be achieved by reacting such constituentcomponents with a negatively electrostatically enhanced water species,perhaps as injected into a gasifier process materials flow path, andmagnetically attracting the reacted constituent component. Moreover,such magnetically isolated constituent components may be removed from agasifier process flow path, for example perhaps by being gravimetricallydeflected away from a gasifier process flow path and received into anelectromagnetic drop well. Such gravimetric deflection of course may beenhanced by a magnet. In various embodiments, such an electromagneticdrop well may be located to receive removed constituent components priorto exit from a temperature varied environment, perhaps even afterpyrolytic decomposition of a feedstock solids carbonaceous material.Removal of such magnetically isolated constituent components further mayreduce abrasion within the solid carbonaceous materials gasifier systemthat otherwise may have been caused by the constituent component. Suchremoval also may assist in increasing the purity of a select productgas, increasing the BTU content of a select product gas, minimizingcontaminants within a select product gas, or perhaps even creating amagnetic materials demagnetized select product gas.

In some embodiments, pyrolytically decomposed carbonaceous material,such as perhaps generated, devolatilized reactive vapor and atomizedparticulate material, may pass into and through a venturi injector (13)(FIGS. 1; 2; 4; 8; 14). This in turn may have a pressure-tight fittingto the inlet of multiple coil carbonaceous reformation vessel (19)(FIGS. 1; 2; 3; 4; 14). A venturi injector (13) (FIGS. 1; 2; 4; 8; 14)may be connected directly to an input, perhaps an inlet pipe opening, ofthe innermost reformation coil (15) (FIGS. 1; 2; 5; 6; 7; 14), perhapspreliminary reformation coil, of a multiple coil carbonaceousreformation vessel. Venturi side-entry inputs may provide the option ofproduced select product gas, generated negatively electrostaticallyenhanced water species, or perhaps both to be injected into thereformation coils, for example perhaps at the initial entry opening ofthe first innermost reformation coil (15) (FIGS. 1; 2; 5; 6; 7; 14). Asan additional process safeguard, a side-stream small volume of selectproduct gas may be made available for return injection such as into themultiple coil carbonaceous reformation vessel (19) (FIGS. 1; 2; 3; 4;14), perhaps even such as into and through the venturi injector (13) orthrough venturi injector (17) (FIGS. 1; 2; 8; 9; 14). This may providefor additional select product gas motive velocity and pressure perhapsto move carbonaceous materials entrained in a gasifier process flowcontinuously into and through all reformation coils (15), (16) and (18)(FIGS. 1; 2; 5; 6; 7; 14) of a multiple coil carbonaceous reformationvessel 19. In the event of a momentary mechanical or process depletionavailability of accessible flue gas, select product gas, or perhapsboth, a rapid shutdown purge may be made available for providing acomplete multiple coil carbonaceous reformation vessel vent-cleaning,perhaps by back-feeding system process water into the multiple coilcarbonaceous reformation vessel (19) (FIGS. 1; 2; 3; 4; 14). Coil latentheat may provide thermal energy to produce an immediate steam cleaningaction, if and when required due to an emergency shutdown circumstance.The availability of providing negatively electrostatically enhanced mistinjection directly into the initial reformation coil, at the point ofventuri injection (13) (FIGS. 1; 2; 4; 8; 14), and/or venturi injector(17) (FIGS. 1; 2; 8; 9; 14), may further provide near instantaneous andimmediate steam reformation reaction-control. If either high surfactantor tarry or waxy chemistry exists, or if very dry input feedstock solidscarbonaceous material is to be processed, or even if additional, perhapsmerely more flexible, process control variables may be desired, anelement such as a venturi injector (17) (FIGS. 1; 2; 8; 9; 14) may beapplied with an alternate embodiment for venturi injector (13) alsoshown.

In some embodiments, a negatively electrostatically enhanced waterspecies, possibly including negatively electrostatically enhanced steam,may be added to a temperature varied environment. Such addition of anegatively electrostatically enhanced water species may represent adynamically adjustable process determinative parameter implemented inthe temperature varied environment. The negatively electrostaticallyenhanced water species perhaps may be routed through a return injectionline (51) (FIGS. 1; 2), and perhaps may be preheated to an elevatedtemperature, such as perhaps about 1,800° F., and may possibly bepreheated via routing through a box furnace enclosure (26) (FIGS. 1; 2;13; 14). Adding the negatively electrostatically enhanced water speciesmay involve mist spraying, perhaps using a venturi (not shown), uponincoming feedstock solid carbonaceous material that may be engaged by atrack feeder (10) (FIGS. 1; 2; 3; 4; 13). External valve control may beincluded to allow the addition of the negatively electrostaticallyenhanced water species to be metered for determining an optimum processcontrol set-point.

Embodiments may further involve adding a flue gas to the temperaturevaried environment, perhaps such a pressurized flue gas, a flue gaspressurized to at least 80 psi, or a flue gas in motion at a rate ofabout 75-100 cfm. Such addition of a flue gas may represent adynamically adjustable process determinative parameter. For example,such addition of a flue gas may be used to further affect temperature ofa feedstock solids carbonaceous material, and may provide motive forcepressurization within the temperature varied environment. For example,perhaps simultaneous to the point of negatively electrostaticallyenhanced water species injection into the temperature variedenvironment, additional hot flue gas may be compressed and pressureregulated, perhaps to at least about 80 psi, from an exhaust flue gascompressor (8) (FIGS. 1; 2; 12). This may be coactively venturi-injected(not shown) such as to perhaps join a spray of the negativelyelectrostatically enhanced water species mixing with incoming feedstocksolids carbonaceous material. This may not only establish furtherprocess determinative parameters that may allow the negativelyelectrostatically enhanced water species to react and assist inaccelerating more complete pyrolytic decomposition, but may also providefor the injection of additional reactive flue gas carbon monoxidecontent, perhaps to accelerate vapor pressure reactions. The injectionof pressurized flue gas also may assist in regulating and perhapsmaintaining pressure within the temperature varied environment, forexample perhaps 80 psi or higher control pressure if desired. Also, heatfrom an added preheated flue gas may be employed to contribute to theoverall heat balance, perhaps reducing heat requirements from othergasifier system elements.

Moreover, embodiments further may provide for adding select product gasto achieve the same process control benefits as adding flue gas, addingwet select product gas, adding dry select product gas, adding recycledselect product gas, adding a scrubber recycled tar, adding a scrubberrecycled phenol, adding scrubber recycled carbon dioxide, and adding ascrubber recycled solid to a temperature varied environment. Suchadditions of course also may represent dynamically adjustable processdeterminative parameters.

Accordingly, in various embodiments, a temperature varied environmentmay incorporate one or more dynamically adjustable process determinativeparameters, perhaps utilized singly or in combination. Initial feedstocksolids carbonaceous materials decomposition, perhaps pyrolyticdecomposition, may occur perhaps across a moving track feederbottom-side length of progressive temperature increase through atemperature gradient. In embodiments, this may range from approximately300° F. to 900° F., and may even occur as movement guides, perhaps trackflights, scrape forward carbonaceous material, as perhaps along asurface of a track feed heater contact plate (not shown). Feedstocksolids carbonaceous material may move forward and may gradually bothdissociate and volatilize into smaller solids and particulates, andinitial carbon conversion gases may be released. Further, the feedstocksolids carbonaceous material may partially liquefy, perhaps along withorganic content beginning to volatilize into hydrogen gas, carbonmonoxide gas, hydrocarbon vapors, and perhaps other select product gascomponents. By controlling and adjusting the retention time, perhapsthrough track feeder speed variation, the feedstock solids carbonaceousmaterial may be subjected to and may pass through the majority of any orall char decomposition reactions, and perhaps liquefaction stages. Theremay even be a near 100% throughput delivery of decomposed, perhapspyrolytically decomposed, carbon-bearing fine particulate material andinitial devolatilized gas cross-over into a subsequent gasifier systemprocessing stage, such as perhaps a multiple coil carbonaceousreformation vessel. Any residual amount of remaining larger-particlechar, solids, or inorganic metallic or inert material, including perhapspara-magnetic organic or metal compounds, may become attracted andisolated into a electromagnetic drop well (12) (FIGS. 1; 2; 13). Theseisolated, perhaps smaller volume materials may be intermittentlytransferred through an airlock receiver (not shown) to an externalcontainer. Any incompletely decomposed carbonaceous material of largerparticle size perhaps may be screen classified and separated away fromother drop-well silica or magnetic debris and recycle returned, such asback to a walking floor feed hopper.

Not only may the physical kinetics of changing track feeder speed allowthe decomposition completion time to become optimized for variouschemistries of different feedstock solids carbonaceous materials, butother synergistic dynamically adjustable process determinativeparameters may be applied, either individually or collectively, perhapsto optimize near total decomposition, and perhaps to maximize initialdevolatilization gaseous transfer such as to subsequent gasifier systemprocessors. Dynamically adjustable process determinative parameters mayexist, perhaps such as: heat and temperature variations which may bealtered or increased; flue gas injected concentrations, perhaps carbonmonoxide ratios, may be adjusted; negatively electrostatically enhancedwater species dilution and injection ratios may be modified toaccelerate carbon shift and steam reformation; throughput select productgas components pressure reaction velocities may be altered; andresultant carry-through vapor and fine, perhaps carbon-bearing,particulate or ash mass balance ratios may be modified and adjusted toachieve optimum select product gas production volumes.

A solid carbonaceous materials gasifier system in various embodimentsmay be configured to recycle various substances routed through agasifier process flow path. Such recycling may involve returningmaterials put through or perhaps generated at a later processing stagewithin the carbonaceous materials gasifier system to an earlierprocessing stage of the carbonaceous materials gasifier system. Invarious embodiments, such return may be via a recycle path appended tothe later processing stage and routed to a recycle input joined to thegasifier process flow path at an earlier processing stage. Moreover,recycling in various embodiments may involve significantly internallyrecycling, for example where a substantial majority of the recyclematerial may be retained within the solid carbonaceous materialsgasifier system, including perhaps all or nearly all of such a recyclematerial. Recycling in various embodiments perhaps even may includeexceeding an environmental standard for recycling such materials.

For example, a generalized process flow for a solid carbonaceousmaterials gasifier system in some embodiments may involve initiallyprocessing at least a portion of a feedstock solids carbonaceousmaterial, creating an initially processed carbonaceous material,subsequently processing the initially processed carbonaceous material,perhaps to generate at least some components of a select product gas,and creating a subsequently processed carbonaceous material. Thesubsequently processed carbonaceous material perhaps may be selectivelyseparated, as into a first processed material portion and a secondprocessed materials portion. The first processed materials portion thenperhaps may be returned, for example perhaps utilizing an appendedrecycle path to a recycle input of the gasifier process flow path. Someembodiments perhaps may involve mixing the returned first processedmaterials portion with an additionally input carbonaceous material, forexample perhaps with a feedstock solids carbonaceous materials re-mixer,and reprocessing.

Of course, the steps of initially processing, subsequently processing,and reprocessing may involve any appropriate kind of processing ofcarbonaceous material consistent with the gasification principlesdiscussed herein—all that may be required is that the step of initiallyprocessing occur before the step of subsequently processing, and thatthe step of subsequently processing occur before the step ofreprocessing. For example, these steps of processing may includepretreating a carbonaceous material, pyrolytically decomposing acarbonaceous material, carbonaceously reforming a carbonaceous materialin a multiple coil carbonaceous reformation vessel, preliminarilycarbonaceously reforming a carbonaceous material in a preliminaryreformation coil, secondarily carbonaceously reforming a carbonaceousmaterial in a secondary reformation coil, and tertiarily reforming acarbonaceous material in a tertiary reformation coil. In addition,returning in various embodiments may be implemented perhaps by aventuri, or perhaps even a venturi injector, for example perhaps tomaintain pressure conditions or flow rate conditions through a recyclepath, for example such as a pressure from about 50 psi to about 100 psior a flow rate from about 2,000 fpm to about 8,000 fpm.

Moreover, recycling in various embodiments may involve selecting arecycle path, perhaps as from a multiply routable path. Such a multiplyroutable path may provide two or more recycle path options through whichrecycled materials may be returned. For example, with reference to thegeneralized process flow described herein, one example of a multiplyroutable path may involve initially processing in a pyrolysis chamber,subsequently processing in a preliminary reformation coil, returning afirst processed materials portion to the pyrolysis chamber, andreprocessing in the pyrolysis chamber. Another example may involveinitially processing in a preliminary reformation coil, subsequentlyprocessing in a secondary reformation coil, returning the firstprocessed materials portion to the preliminary reformation coil, andreprocessing in the preliminary reformation coil. Of course, these aremerely examples illustrative of some possible configurations for amultiply routable path in some embodiments, and should not be construedto limit the possible configurations for a multiply routable pathconsistent with the principles described herein.

In various embodiments, materials routed through a gasifier process flowpath may be selectively separated. Such selective separation perhaps mayinvolve selecting a property of the material to be separated andeffecting separation by utilizing that property. Examples of suchselective separation perhaps may include screening, solubilization,magnetism, or the like. In some embodiments, selective separation may beaccomplished through the vortex action of a cyclone. For example,embodiments may include operating a cyclone at conditions includingperhaps from 50 psi to 100 psi, 1,640° F. to 1,800° F., and 2,000 fpm to8,000 fpm, and achieving the selective separation of gasifier processflow path materials accordingly. Moreover, selectively separating mayinclude on the basis of particle size, for example perhaps selectivelyseparating carbonaceous particles of at least 350 micron particle size,selectively separating carbonaceous particles of at least 150 micronparticle size, selectively separating carbonaceous particles of at least130 micron particle size, selectively separating carbonaceous particlesof at least 80 micron particle size, selectively separating carbonaceousparticles of at least 50 micron particle size, selectively separatingcarbonaceous particles of at least 11 micron particle size, selectivelyseparating carbonaceous particles of at least 3 micron particle size,and selectively separating ash. Other modes of selectively separatingmay include physically separating, separating by phase, separating bydensity, separating by screening, separating by incompletelypyrolytically decomposed carbonaceous material, separating byincompletely carbonaceously reformed material, separating byheterogeneous composition, and the like. Moreover, selectivelyseparating consistent with the techniques described herein may removecertain impurities from a gasifier process flow, perhaps with the resultof increasing the purity of a select product gas, increasing the BTUvalue of a select product gas, or perhaps minimizing contaminants withina select product gas. In various embodiments, such resulting productsmay be considered to be separation products resulting from the act ofselectively separating as described herein.

A gasifier process flow path in various embodiments may be routedthrough a multiple coil carbonaceous reformation vessel (19) (FIGS. 1;2; 3; 4; 14). For example, a process flow may include pyrolyticallydecomposed carbonaceous materials from a pyrolysis chamber, perhaps suchas released gas and carbon-bearing particulate matter pressurized out ofa temperature varied environment. A multiple coil reformation vessel mayinclude two or more reformation coils through which a process flow maybe routed. Carbonaceous materials entrained in the process flow may bereformed within each such reformation coil. Such carbonaceousreformation may encompass perhaps simply changing the form of suchcarbonaceous materials, as for example perhaps from or into selectproduct gas components, from or into incompletely reformed carbonaceousmaterials, from or into ash, or perhaps from or into various types ofcontaminants. In some embodiments, carbonaceous reformation may involvevaporizing a carbonaceous material, for example such as vaporizinghydrocarbons or vaporizing select product gas components. Moreover,reformation coils perhaps may simply provide a coiled path through whicha process flow may be routed during a carbonaceous reformation stage ina solid carbonaceous materials gasifier system, in some embodiments forexample as perhaps through a coiled tube, pipe, conduit, or the like. Amultiple coil carbonaceous reformation vessel may include a preliminaryreformation coil, a secondary reformation coil, a tertiary reformation,and perhaps one or more additional reformation coils as may be desiredto achieve carbonaceous reformation.

Embodiments may include complementarily configuring at least tworeformation coils, which may involve positioning the reformation coilsrelative to each other to improve the efficacy of the carbonaceousreformation process. For example, some embodiments may involve helicallynesting at least two carbonaceous reformation coils. Such a helicallynested arrangement perhaps may improve the efficacy of the carbonaceousreformation process by reducing the size occupied by a multiple coilcarbonaceous reformation vessel, or perhaps by permitting the selectivedistribution of heat applied to the helically nested configuration, suchas wherein heat may be applied to one coil and radiated from that coilto another helically nested coil. In this manner, individual reformationcoils may be seen to act as radiators. For example, embodiments mayinvolve a preliminary reformation coil, a secondary reformation coil,and a tertiary reformation coil in a helically nested configuration,wherein heat applied to the helically nested configuration may bevariably triply distributed from one coil to another, and theconfiguration may act as a tripart reformation coil radiator. Of course,it may be appreciated that the manner in which two or more reformationcoils may be complementarily configured and the location and modality inwhich heat may be selectively applied may create a variety ofarrangements that may represent selectively adjustable process controlparameters, perhaps even dynamically adjustable process determinativeparameters.

For example, in some embodiments, a horizontal helically nestedconfiguration of multiple reformation coils such as one inside the othermay be applied. Such a configuration may provide a high temperaturehelical coil reformation environment that may establish the longestlength within the smallest cube design volume space and footprint,perhaps as shown in assembly (19) and embodiments (15), (16) & (18)(FIGS. 1; 2; 3; 4; 5; 6; 7; 14). As one example, assembly (19) may havea nesting configuration design that may provide an extremely efficientheat transfer cubical unit whereby the maximum amount of helicalreformation coil lineal footage of pipe is packed into the smallestcubic volume of box furnace enclosure (26) (FIGS. 1; 2; 13; 14) space.This configuration may provide radiant heat transfer from the outermostcoil (18) (FIGS. 1; 2; 5; 6; 7; 14) to the innermost coil (15) (FIGS. 1;2; 5; 6; 7; 14) and vice versa. This may reduce an overall furnace BTUcombustion heat and the input select product gas energy requirement asnecessary such as perhaps to hold the furnace temperature constant inthe 1,600° F. to 1,800° F. temperature range.

The helical reformation coil assembly (19) inside of the furnace may beheated and held at an elevated level, perhaps such as from about 1,600°F. to about 1,800° F. Further, the furnace may be heated by acomputerized and auto-controlled combustive burner manifold system (14)(FIGS. 1; 2; 14; 9). A combustive burner may utilize recycled selectproduct gas as the combustible fuel source, perhaps with an alternateconnection to an external fuel source, perhaps a pressurized propanetank, to be supplied as an initial startup fuel source or the like. Inthe helical reformation coil assembly 19, a burner manifold forced aircombustion system may hold the temperature of all three reformationcoils (15), (16) and (18) (FIGS. 1; 2; 5; 6; 7; 14) elevated, perhapssuch as at a minimum of about 1,600° F. in order to facilitatecarbonaceous reformation, as for example where substantially allatomized carbon particulate material moving through the combined lengthof all three reformation coils may be substantially completelycarbonaceously reformed (perhaps such as in the presence of steam) intoselect product gas components, such as perhaps carbon monoxide andhydrogen gases. In embodiments, a combustive burner manifold system (14)(FIGS. 1; 2; 14) may be placed on the inside of the box furnaceenclosure (26), for example perhaps at the bottom inside wall andperhaps further extended one-third upward on two opposing sidewalls (notshown). Burner jet-nozzles may penetrate through the box furnaceenclosure (26) (FIGS. 1; 2; 13; 14), perhaps with pressure-tightweldments, and perhaps may further penetrate through a perhaps twelveinch thickness of high temperature glass wool insulation (perhaps withceramic heat shield cones placed around each burner jet-nozzle pipe).Nozzles may be strategically angle positioned to produce a selectivelyapplied heat distribution, such as perhaps an evenly distributed blanketof heat across the entire reactor embodiment surfaces (and perhapsthroughout the three-dimensional helical nest structure) of the helicalreformation coil configuration (19) (FIGS. 1; 2; 3; 4; 14). To providemaximum heat and strength longevity, the reformation coils (15), (16)and (18) (FIGS. 1; 2; 5; 6; 7; 14) may be fabricated from high strengthand high temperature Inconel® or other such metal pipe, or otheralternate and appropriate metallic materials. Reformation coil (such asper each nesting coil) diameters may vary from about three inches toabout eight inches in diameter and the pipe lengths may varyproportionally as dependent upon the daily tonnage of input feedstockvolume that is to be processed, perhaps in order to maintain optimumprocess gas velocity throughout the multiple carbonaceous reformationcoil vessel and any selective separators incorporated therein.

Operating conditions of a preliminary reformation coil, perhaps asexemplified within helical reformation coil assembly (19), may includean operating condition of at least 50 psi to 100 psi, 1,640° F. to1,800° F., and a flow rate from 5,000 fpm to 20,000 fpm. Similarly,operating conditions of a secondary reformation coil, perhaps asexemplified within helical reformation coil assembly (19), may includean operating condition of at least 50 psi to 100 psi, 1,640° F. to1,800° F., a flow rate from 5,000 fpm to 20,000 fpm, and perhaps areformation time of up to about 5 seconds. Moreover, operatingconditions of a tertiary reformation coil, perhaps as exemplified withinhelical reformation coil assembly (19), may include an operatingcondition of at least 50 psi to 100 psi, 1,750° F. to 1,850° F., a flowrate from 5,000 fpm to 20,000 fpm, and perhaps a reformation time of upto about 4 seconds. Total reformation time of a multiple coilcarbonaceous reformation vessel, again as perhaps exemplified by helicalreformation coil assembly (19), may be from about 4 seconds to about 10seconds.

Moreover, embodiments may include adding reaction beneficial materialsto at least one reformation coil of a multiple coil reformation vessel,for example such as adding before a preliminary reformation coil, addingbetween a preliminary reformation coil and a secondary reformation coil,adding between a secondary reformation coil and a tertiary reformationcoil, adding after a tertiary reformation coil, utilizing a venturiinjector, utilizing a flue gas, utilizing a pressurized flue gas,utilizing a preheated flue gas, and perhaps via a reaction beneficialmaterials input.

Carbonaceously reforming within a multiple coil carbonaceous reformationvessel in various embodiments may include selectively separatingcarbonaceous materials at various points within the vessel with acarbonaceously reformed materials selective separator, for exampleperhaps via vortex action using a cyclone. One or more selectiveseparators perhaps may be employed and placed at suitable locationswithin the multiple coil carbonaceous reformation vessel, for exampleperhaps to achieve selective separation before a preliminary reformationcoil, between a preliminary reformation coil and a secondary reformationcoil, between a secondary reformation coil and a tertiary reformationcoil, and perhaps after a tertiary reformation coil. Selectivelyseparating in this manner perhaps may allow progressive refinement of aquality of a carbonaceous material as it is routed through thereformation coils of a multiple coil reformation vessel, for example,perhaps by progressively reducing the particle size of carbonaceousparticles transiting from coil to coil. Moreover, such selectivelyseparated carbonaceous materials may be recycled, for example via acarbonaceously reformed materials recycle path, to any suitable gasifierprocess flow path location, such as a pretreatment area, a pyrolysischamber, a preliminary reformation coil, a secondary reformation coil,and perhaps by utilizing a venturi injector, utilizing a flue gas,utilizing a pressurized flue gas, utilizing a preheated flue gas, or thelike.

In some embodiments, for example, a cyclone (20) (FIGS. 1; 2; 14)perhaps may be fitted to an end outlet of a preliminary reformation coil(15) (FIGS. 1; 2; 5; 6; 7; 14). Such a cyclone may be fabricated fromhigh temperature Inconel® or other alternate and appropriate metallicmaterials or the like. In embodiments, a cyclone perhaps may beengineered to remove carbonaceous materials, such as perhaps themajority of char carry-through particulate material such as that isabout 80 to about 150 microns in particle size, or larger. A venturi,perhaps a venturi injector, may be joined at the cyclone bottom exitport, and perhaps may control a periodic emptying of accumulatedselectively separated carbonaceous materials, perhaps such as chardebris, for recycling back such as into a pyrolysis chamber. Suchrecycling perhaps may allow additional pyrolytic decomposition of therecycled carbonaceous material, for example carbon containing charparticulates, to occur. The venturi, perhaps a venturi injector, may beprovided with a side-stream injection port from a produced selectproduct gas delivery manifold (21) (FIGS. 1; 2; 8; 9; 14) and may alsoprovide perhaps a variable differential pressure that may assist inclearing the cyclone of selectively separated carbonaceous material.Moreover, a venturi injector unit (17) (FIG. 3) may be connected,perhaps flange connected, to the top outlet of the cyclone (20), andperhaps may utilize nuclear industry design high temperature flexatalicgaskets and bolt assemblies. A venturi injector (17) further may beconnected, perhaps flange connected, such as to an inlet opening of asecondary reformation coil (16) (FIGS. 1; 2; 5; 6; 7; 14) and perhapsmay provide additional turbulent flow steam reformation into thereformation coil (16).

A carbonaceous materials selective separation sequence perhaps may berepeated for a secondary reformation coil, perhaps relative to applyinga cyclone (22) (FIGS. 1; 2; 14). A cyclone (22) may act to removecarbonaceous materials, perhaps such as carry-through char particulatesdown to about 50 to about 130 microns in particle size, perhaps byconnecting, perhaps flange connecting, the cyclone from an exit openingof the secondary reformation coil (16) (FIGS. 1; 2; 5; 6; 7; 14) to theentry opening of the tertiary reformation coil (18) (FIGS. 1; 2; 5; 6;7; 14). A venturi injector (17) (FIGS. 1; 2; 8; 9; 14) may be alsoinstalled, as perhaps within pipe flange connections between the topexit of the cyclone classifier (22) and the entry point into thetertiary reformation coil (18). This additional installed location of aventuri injector (17) (FIGS. 1; 2; 8; 9; 14) may further provideaccelerated carbonaceous reformation, perhaps to additionally decreaseCO₂ and other hydrocarbon concentrations in the select product gasstream being generated. As with the cyclone (20) (FIGS. 1; 2; 14), abottom exit venturi, perhaps venturi injector possibly with recycledselect product gas side-stream injection, may be provided that may workon differential pressure to periodically empty selectively separatedcarbonaceous material, such as char particulate material, perhapsrecycled back such as into the pyrolysis track feeder or into apreliminary reformation coil. This may provide for the recycle recoveryof carbonaceous materials, perhaps such as most all char organic carboncontent, perhaps via the re-processing of recovered char particulatematerial within a preliminary reformation coil.

Two cyclones (23) (FIGS. 1; 2; 14), perhaps tertiary final polishcyclone classifiers, may be included and may be connected, perhapsflange connected, to an exit opening such as of a tertiary reformationcoil (18) (FIGS. 1; 2; 5; 6; 7; 14). These perhaps may be provided aspipe arrangements in series with each other, and perhaps may selectivelyseparate and remove any remaining carbonaceous materials or ashcarry-through particulate material, for example perhaps in the particlesize removal ranges of: 10% of 1 micron size particles being removed;25% of 2 micron size particles being removed; 35% of 3 micron sizeparticles being removed; and even 100% of 15 micron size (or aboveparticle size) particles being removed. In embodiments, twoseries-staged polishing cyclones (23) may be utilized perhaps to ensurethat any possible post contamination of carbonaceous materials, such asperhaps still reactive char materials, or ash substrate carrying throughto contaminate final produced select product gas may be avoided.Further, an ash removal system, perhaps such as an auto-purge doubleair-lock valve system, may be employed such as to perhaps periodicallyempty any fine ash particulate material from such cyclones into an ashreceiver system and automated removal section.

A gasifier process flow path in various embodiments may be routedthrough an ash removal area (78) (FIGS. 1; 2) of a solid carbonaceousmaterials gasifier system. This may be illustrated conceptually in oneembodiment in FIGS. 1 & 2. In embodiments, fine particulate materialperhaps may pass through a multiple coil carbonaceous reformationvessel. This fine particulate material may be substantially, perhapseven 95% or more, selectively separated via cyclones (23) (FIGS. 1; 2;14). The majority of these selectively separated fine particulatematerials may be inert and may exist as non-carbon and non-reactive ashsubstrate. Such ash substrate material may be selectively separated fromthe gasifier process flow path perhaps to eliminate nearly allparticulate contamination and perhaps to ensure that a high qualitypurity of the final select product gas is maintained.

An ash removal handling system, perhaps airtight and pressurized, may beprovided whereby two cyclones (23) (FIGS. 1; 2; 14) each may emptycollected ash, perhaps via a sealed conduit pipe connection through abox furnace enclosure (26) (FIGS. 1; 2; 13; 14), and perhaps such asinto smaller ash receiver tanks (24) (FIGS. 1; 2; 15). The ash may bewithdrawn from the two cyclones perhaps through a dual airlock andtriple, perhaps slide actuation, valve system (7) (FIGS. 1; 2; 15). Inembodiments, as the top and bottom valves may actuate to the openposition, the middle valve may remain closed. Intermittently, hot ashmay fall by gravity into the top receiver tank and the bottom receivertank (24) (FIGS. 1; 2; 15). Ash from the bottom receiver tank (perhapssomewhat cooled) may fall down and into an elliptical conveyor screwtrough and separated ash recovery unit (25) (FIGS. 1; 2; 15) perhaps tobe subsequently transported to adjacent mobile storage, perhaps coolingbins. Valves, such as slide valves (7) may be air-operated and may cycleopen and closed on a reciprocal time basis perhaps such as perhapsapproximately every 30 minutes or as controlled by process computerset-points. Adjustable time frequency of valve actuation may provide foradditional ash cooling time to occur within the ash receiver tank (24).Further, ash receiver tanks and even the slide valve assemblies may beconstructed of high temperature steel materials. The removed ash,perhaps as dependent upon the input carbonaceous feedstock chemicalcomposition, may represent an item with resale potential as a high grademineral fertilizer additive, and perhaps may be applied as acementaceous filler in cement construction block manufacturingoperations.

A solid carbonaceous materials gasifier system in various embodimentsmay generate a contaminated select product gas. Such contaminants mayinclude perhaps simply any substances tending to reduce the quality of aselect product gas. Examples of such contaminants may include forexample chemical by-products, thermal by-products, pyrolyticdecomposition by-products, carbonaceous reformation by-products, carbondioxide, carbonate, insoluble solids, tar, phenol, hydrocarbon, andother particulates. Accordingly, embodiments may provide for isolating asignificant number of contaminants and creating a scrubbed selectproduct gas. This may be illustrated conceptually in process embodimentsin FIGS. 1 & 2. Such isolation may be accomplished in any suitablemanner consistent with the principles discussed herein, for exampleperhaps by pyrolysis, screening, magnetism, vortex action, or the like.In some embodiments, such isolation may be accomplished by solubilizingthe contaminants in a contaminant solubilization substance, perhaps asmay be disposed within a select product gas components scrubber throughwhich said gasifier process flow path may be routed. Such solubilizationfurther may comprise increasing the purity of a select product gas,increasing the BTU value of a select product gas, minimizingcontaminants within a select product gas, or perhaps even creating ascrubbed select product gas having one or more of these properties,consistent with the principles described herein.

A contaminant solubilization substance in certain embodiments mayinclude a negatively electrostatically enhanced water species.Contaminant isolation may occur upon solubilization of contaminants insuch a negatively electrostatically enhanced water species, perhaps viaan oxidation reaction, a reduction reaction, an adsorption coagulationreaction, an absorption coagulation reaction, or the like. Accordingly,such solubilization may involve coagulating, separating, flocculating,precipitating, settling, condensing, polishing, filtering, removing viafinal polarized media polish filtration, and removing viaelectro-precipitation removal such contaminants.

Contaminant solubilization substances also perhaps may include chilledcontaminant solubilization substances. For example, embodiments mayinclude lowering the temperature of a select product gas via a chilledcontaminant solubilization substance in a select product gas componentsscrubber, for example as from greater than about 1700° F. to less thanabout 175° F. Moreover, such use of a chilled contaminant solubilizationsubstance to lower the temperature of a select product gas may preventvitrification solidification of contaminants within the select productgas as it is cooled, with contaminants instead perhaps being solubilizedin the contaminant solubilization substance with decontaminated selectproduct gas being maintained in an unvitrified state.

Moreover, a select product gas components scrubber in variousembodiments may include at least a primary solubilization environmentand a secondary solubilization environment, for example perhaps aprimary scrubber tank and a secondary scrubber tank. Such multiplesolubilization environments perhaps may provide multiple stage scrubbingof a select product gas, for example as wherein one scrubbing stage maybe insufficient to accomplish a desired level of scrubbing, or aswherein it may be desirable to spread various scrubbing steps overseveral stages, such as perhaps for reducing a temperature of a selectproduct gas being scrubbed. For example, primarily solubilizing in aprimary solubilization environment in some embodiments perhaps may beconfigured to lower a temperature a select product gas from greater than1,700° F. to less than 550° F., and secondarily solubilizing in asecondary solubilization environment perhaps may be configured to lowera temperature a select product gas from greater than 450° F. to lessthan 150° F. Of course, multiple stage scrubbing may address otherprocess parameters, for example as wherein a primary solubilizationenvironment may be configured to remove 70% to 80% of contaminants froma select product gas, with a second solubilization environmentconfigured to remove perhaps some additional fraction of remainingcontaminants.

Accordingly, embodiments may involve mixing and injecting one or morenegatively electrostatically enhanced water species, such as perhaps alarge portion of ionized and perhaps highly reactive oxygen vapor gasesperhaps utilizing singlet oxygen, into a select product gas componentsscrubber through which a gasifier process flow path may be routed.Contaminants entrained in the gasifier process flow path perhaps maythen be solubilized into the water species. Such contaminants perhapsmay be further removed from the water species in one or more of severalseparating devices which may be incorporated into the select product gascomponents scrubber. In such arrangements, negatively electrostaticallyenhanced water species and hot synthesis gas reaction contact may takeplace. Coalescence and oxidation of contaminants may occur and may causeCO₂ (perhaps oxidized to CO₃ agglomerates), insolubles, tars, phenols,and other hydrocarbon contaminants to flocculate, precipitate, and/orperhaps settle for final polarized media polish filtrationelectro-precipitation removal of said contaminants.

Moreover, embodiments of the inventive technology may provide additionalselect product gas final purification and cleanup systems. Some of thesemay be as specifically indicated in the depiction of an embodiment suchas shown in a scrubber area (79), (FIGS. 1; 2; 16), which may include(but may not require) elements as follows:

-   -   element (27): an Insulated Crossover Pipe (perhaps 1800° F.        Synthesis Gas) To Scrubber Tank Inlet Cylinder,    -   element (28): a Mix (perhaps Synthesis Gas/VIP™/Ionized Water)        Injector Cylinder,    -   element (29): a VIP™ (Vapor Ion Plasma) Ionized Water And        Synthesis Gas Primary Scrubber Tank With Temperature Reduction        perhaps To 350° F.,    -   element (30): a VIP™ Ionized Water Spray Manifold,    -   element (31): a VIP™ Vapor Ion Plasma Generator,    -   element (32): a VIP™ Injection Ionized H₂O Spray Diffusers,    -   element (33): a Recirculation Flow (perhaps Doubled Walled) Tank        and chilled water separation tank, such as for Tar/Phenols        prop-Out, element (34): an Auto-Control H₂O Balance Valves,    -   element (35): a VIP™ Ionized Water and Synthesis Gas Secondary        Scrubber Tank, such as for Final Hydrocarbon(s) Removal,    -   element (36): a Scrubber H₂O Recycle Recirculation Pump,    -   element (37): a VIP™ Cooling H₂O Return Manifold,    -   element (38): a Chilled Water Tank (Tars/Phenols) Bleed-Off        Return perhaps As Recycle Recovery Back To a pyrolytic        decomposition area (75) Track Feeder Devolatilization Zone, or        perhaps To Be Separated In an auxiliary treatment area (76)        Roto-Sheamm Concentrator Unit,    -   element (39): a Synthesis Gas (perhaps 350° F. Crossover) Pipe        To Secondary Scrubber Tank,    -   element (40): a (perhaps Auto-Controlled) Temperature Chiller,    -   element (41): an Air/Liquid perhaps Serpentine Heat Exchanger,    -   element (42): a Delivery (perhaps 80° F.) Manifold To        electrically filter (eFILT™) perhaps via a Polarized Media        Filter,    -   element (43): an eFILT™ (perhaps Polarized Media Filter)        Recirculation Pump,    -   element (44): an eFILT™ Influent Filtration Manifold,    -   element (45): an eFILT™ perhaps Polarized Media Filter, Per Fine        (perhaps One Micron Particle Size) Solids Removal, Including        “CO₂ Shift To CO₃” Removal,    -   element (46): a VIP™ Ionized H₂O and Solids Slurry By-Pass Line        to Embodiment (51),    -   element (47): a Filtered VIP™ perhaps Ionized H₂O Recycle Return        To Primary Scrubber Tank,    -   element (48): an eFILT™ Backwash Water To Holding and Settling        Tank,    -   element (49): a Backwash H₂O Slurry Holding and Settling Tank,    -   element (50): a Recirculation Chilled Water Separation Tank        Overflow,    -   element (51): a Common (VIP™/Ionized H₂O/Solids) Return To Track        Feeder Injection,    -   element (52): a Synthesis Gas Side-Stream Manifold Feed To        Reactor Combustion Burner,    -   element (54): a Polish (H₂O Removal) Coalescer and Condenser,    -   element (55): a Polish Synthesis Gas (Fine Micron) Filters,    -   element (56): a Backwash Solids Roto-Shear (rS™) Screw        Concentrator and Separator,    -   element (57): a Scrubber Tank Level Indicator and Controller,    -   element (58): a System Components Overflow Drain Line,    -   element (59): an Overflow Holding Tank and a VIP™ Ionized H₂O        and Backwash H₂O Collection Tank,    -   element (60): a Synthesis Gas Delivery Compressor,    -   element (61): a Drain Line To Systems Collection Receiver        Flash-Evaporator Unit,    -   element (62): a VIP™ Ionized H₂O Pump,    -   element (63): an Outside Makeup Water Line,    -   element (64): a Filter Backwash Water Input Line,    -   element (65): a Concentrated Solids Transfer To (perhaps        External) Recovery Unit,    -   element (69): a Final CO₂ Separation (perhaps Molecular Sieve        Unit) if required,    -   element (70): a Final Output Highly Purified [perhaps 550 BTU to        650 BTU] Synthesis Gas (perhaps Stripped of NOx, SOx, CO₂ and        Organic Vapors) Stream,    -   element (71): a Safety (perhaps Auto-Pressure) Relief Valve,    -   element (72): an External Flare (perhaps Auto-Ignition) System,        and    -   element (73): a VIP™ Ionized H₂O and Solids Slurry Pump.

In various embodiments, at least some isolated contaminants may berecycled within a solid carbonaceous materials gasifier system andreprocessed therein. Accordingly, embodiments may involve returning suchisolated contaminants, for example via a contaminants recycle pathappended to a select product gas components scrubber and returning to acontaminants recycle input of a gasifier process flow path. Moreover,such recycling may involve selecting a recycle path, perhaps as from amultiply routable path. Such a multiply routable path in someembodiments may be routed through a feedstock solids carbonaceousmaterials processor, a select product gas components scrubber, acontaminants recycle path, and a contaminants recycle input of agasifier process flow path. Moreover, in various embodiments, routing acontaminants recycle path to a contaminants recycle input may involverouting to a recycle input of a pretreatment area, pyrolysis chamber,multiple coil carbonaceous reformation vessel, preliminary reformationcoil of a multiple coil carbonaceous reformation vessel, secondaryreformation coil of a multiple coil carbonaceous reformation vessel, ora tertiary coil of a carbonaceous reformation vessel. Additionally, acontaminants recycle path in various embodiments may include a venturi,or perhaps even a venturi injector, for example perhaps to assist inmoving contaminants through the recycle path.

Various embodiments may include a select product gas componentsformation zone through which a gasifier process flow path is routed.Consistent with the principles described herein, such a select productgas components formation zone perhaps simply may be any portion of agasifier process flow path in which select product gas components may beformed. For example, processing stages tending to generate carbonmonoxide content select product gas components, hydrogen content selectproduct gas components, or perhaps controlled molar ratio select productgas components may be select product gas components formation zones invarious embodiments. Moreover, embodiments also may include a selectproduct gas formation zone. Again, consistent with the principlesdescribed herein, such a select product gas formation zone perhapssimply may be any portion of a gasifier process flow path in which aselect product gas may be formed. Of course, such a select product gasmay include any of various characteristics as described elsewhereherein.

A gasifier process flow path in various embodiments may be routedthrough a product gas combustion preparation auxiliary treatment area(76) (FIGS. 1; 17). Embodiments may provide the return of a side-streamof produced select product gas, perhaps combustible 550 BTU to 650 BTUper pound, perhaps as from a produced select product gas outlet conduitpipe (52) (FIGS. 1; 2) to a combustive burner (14) (FIGS. 1; 2; 14).This may further extend from the produced gas outlet pipe (52) toprovide an optional select product gas feed to a venturi feed pipe (53)(FIGS. 1; 2; 17), perhaps a venturi injector, providing inlet access toa multiple coil carbonaceous reformation vessel or the like. Combustionsustaining operations fuel may be autonomously provided by a recyclereturn, perhaps at a level of 15% or less of the total select productgas volume being generated.

Embodiments may include an air separation unit (66) (FIGS. 1; 2; 17),perhaps including an air intake and a nitrogen depletion area to depleteat least some nitrogen from taken in air. In this manner, a supply ofenriched oxygen air flow may be generated and nitrogen content perhapsmay be reduced within a solid carbonaceous materials gasifier system.For example, an oxygen enrichment line may be routed to a combustiveburner whereby oxygen concentration input may be increased, for exampleperhaps such as by approximately 30%, which may in turn reduce a recyclerequirement of select product gas such as to support furnace combustionoperational temperatures, at a level of perhaps less than 10% of therecycle requirement. Moreover, an air separation unit (66) (FIGS. 1; 2;17) may greatly deplete the nitrogen content in a combustion air intakestream, for example as may supply combustion operations at one or morecombustive burners, which may substantially reduce process carry-throughof nitrogen contaminants into the gasifier process flow path, includingperhaps the final produced select product gas. Nitrogen oxidescontamination and emission possibilities may be greatly reduced,eliminated, or may even become virtually non-existent. A combustionadjustable baffle proportioning flow air fan (67) (FIGS. 1; 2; 17) maybe provided to meter atmospheric air intake, with recycled selectproduct gas (perhaps with air separation unit (66) enriched oxygen airflow), perhaps as a forced draft combustible admixture gas flow into acombustive burner (14). Additionally, a side-stream oxygen enrichmentline (68) (FIGS. 1; 2; 17) may be connected, perhaps as a bypass pipeconnection, to a negatively electrostatically enhanced water speciesgeneration unit, for example perhaps one or more VIP™ Vapor Ion Plasmagenerator units (31) (FIGS. 1; 2; 10; 16). The input addition of a moreconcentrated oxygen addition to such units, for example such as anactivated oxygen content, may greatly enhance the output of negativeelectrostatic enhancement species, for example perhaps vapor ion plasmasinglet oxygen or peroxyl ion concentrations as injected into an ionizedoxygen water stream, as may be applied throughout a solid carbonaceousmaterials gasifier system in various embodiments. Accordingly,embodiments may provide for a nitrogen depleted select product gas,which in fact may be a nitrogen oxide content minimized select productgas, a purified select product gas, or even a high BTU content selectproduct gas.

A solid carbonaceous materials gasifier system in various embodimentsmay subject to an input feedstock solids carbonaceous material to avariety of chemical reaction sequences. A basic chemical reactionsequence often considered in the production of synthesis gas may berepresented in Table 1 as follows, though the inventive technology maybe applicable to a variety of chemical reaction sequences and should notbe considered as limited to just the following:

TABLE 1

In some embodiments, process determinative parameters of the inventivetechnology may permit manipulation of this and other chemical reactionsequences, and indeed perhaps even non-chemical processing aspects, in asolid carbonaceous materials gasifier system to generate high energycontent, purified, or even high yield select product gas, perhaps suchas by finishing the chemical reaction sequence to substantial completionfor a majority of or perhaps substantially all of the carbon content ina feedstock solids carbonaceous material. For example, embodiments mayinvolve dynamically adjusting at least one such process determinativeparameter, as perhaps with a dynamically adjustable process flowregulator. The dynamic character of such an adjustment may stem from thecapability of effecting such adjustments while the gasifier system isoperating. For example, embodiments may include sensing at least oneprocess condition with a process condition sensor and adjusting at leastone process determinative parameter with a sensor responsive dynamicallyadjustable flow regulator based on the sensed condition. Sensing, ofcourse, may be accomplished in any of a variety of suitable manners,such as sensing a temperature, sensing a pressure, sensing a processmaterials composition, sensing a carbon monoxide content, sensing acarbon dioxide content, sensing a hydrogen content, sensing a nitrogencontent, sensing a sulfur content, sensing via a gas chromatograph,sensing via a mass spectrometer, and the like. Similarly, any of avariety of adjustments may be dynamically affected in response by anappropriate process flow regulator, such as suitable inputs, injectors,separators, returns, timers, and the like. Examples of such adjustmentsmay include adding water, adding preheated water, adding recycled water,adding a negatively electrostatically enhanced water species, adding apreheated negatively electrostatically enhanced water species, adding arecycled negatively electrostatically enhanced water species, addingsteam, adding recycled steam, adding negatively electrostaticallyenhanced steam, adding recycled negatively electrostatically enhancedsteam, adding flue gas, adding preheated flue gas, adding pressurizedflue gas, adding recycled flue gas, adding a recycled incompletelypyrolytically decomposed carbonaceous material, adding a recycledincompletely reformed carbonaceous material, adding at least onerecycled contaminant, adding at least some select product gas, adding atleast some wet product gas, adding at least some dry select product gas,adding at least some recycled select product gas, varying a processretention time, varying a process flow rate, varying a process flowturbulence, varying a process flow cavitation, varying a selectivelyapplied heat distribution among multiple reformation coils, varying atemperature gradient in a temperature varied environment, varying aliquefaction zone in a temperature varied environment, selectivelyseparating a carbonaceously reformed material, and the like. In someembodiments, these parameters may be process determinative in that theiradjustment may affect and therefore perhaps determine the outcome ofsolid carbonaceous materials processing in the gasifier system.

Moreover, such dynamic adjustments may be effected at any suitable pointof a gasifier process flow path with an appropriate input, includingperhaps at a pretreatment area, at a pyrolysis chamber, at a multiplecoil carbonaceous reformation vessel, at a select product gas componentsscrubber, and the like, perhaps even as may be embodied in someembodiments in a modular section of such a gasifier system. Additionallyconsistent with the dynamic character of such adjustments, theadjustments perhaps may be automatically effected, perhaps such as bycomputer control. Such dynamic adjustments may permit fast response timeimplementation of the adjustments, perhaps in times as little as lessthan 0.5 seconds, less than 1 second, less than 2 seconds, less than 3seconds, less than 4 seconds, less than 5 seconds, less than 10 seconds,less than 15 seconds, less than 30 seconds, less than 45 seconds, lessthan 60 seconds, less than 90 seconds, and the like.

Various embodiments of course may involve effecting these dynamicadjustments in a variety of suitable modalities. For example,embodiments may include establishing an adjustable set point andperiodically testing a process condition. Such a set point may involvecarrying out processing to a set specification, such as a set time,temperature, pressure, or the like. In this manner, periodically testinga process condition, for example by measuring a processing time,temperature, pressure, or the like, may allow determination ofprocessing conditions relative to the set point and appropriate dynamicadjustment if actual processing conditions are off. Further examples ofsuitable modalities may include evaluating a feedstock solidscarbonaceous material, as with perhaps a feedstock evaluation system,for example by characteristics such as chemistry, particle size,hardness, density, and the like, and responsively dynamically adjustingprocess flow conditions accordingly. In some embodiments, responsivedynamic adjustments may involve affecting a select product gas, forexample perhaps by increasing the purity, increasing BTU content,reducing contaminants, or creating a select product gas having one ormore of these properties.

Embodiments may involve affirmatively establishing a stoichiometricallyobjectivistic chemic environment. This perhaps may involve establishingconditions, as within a pressurized environment to which a feedstocksolids carbonaceous material may be subjected, having as an object theconversion of the feedstock solids carbonaceous material into a desiredproduct, for example perhaps a desired select product gas. Such anenvironment of courses may be chemic, which may involve chemicalinteractions in which one or more components of the feedstock solidscarbonaceous material may participate, or perhaps even simplynon-chemical conditions related to such chemical interactions, forexample such as temperature conditions, pressure conditions, phaseconditions, or the like. Stoichiometric analysis may be utilized toaffirmatively identify significant relationships among the components ofthe feedstock solids carbonaceous material and the desired product, forexample such as quantity amounts of such components or perhaps chemicalreaction sequences by which the feedstock solids carbonaceous materialmay be converted into the desired product. Where appropriate,stoichiometric compensation may be utilized to add or remove chemicalcomponents according to the identified relationships, for exampleperhaps to create an overall balance of components in proportion to theidentified relationships. In various embodiments, stoichiometriccompensation may be accomplished in a solid carbonaceous materialsgasifier system via stoichiometrically objectivistic adjustmentcompensators, for example such as any of various suitable inputs,outputs, injectors, purges, dynamically adjustable process flowregulators, and the like, consistent with the principles describedherein.

Some embodiments may involve stoichiometrically controlling carboncontent in a manner significantly appropriate for a select product gas.This perhaps may involve applying the stoichiometric principlesdescribed herein to the relationship between the carbon content of afeedstock solids carbonaceous material and a carbon content of an objectselect product gas to be produced. For example, such stoichiometricapplications may involve changing carbon quantities through variousprocessing stages of a solid carbonaceous materials gasifier system.Processing may involve adding carbon content throughout a gasifierprocess flow path, such as to ensure sufficient quantities of carbon forcomplete interaction with other processing materials throughout thevarious processing states of the solid carbonaceous materials gasifiersystem. An object may be to achieve a target carbon content in a selectproduct gas, for example perhaps according to the molar ratios ofchemical reaction sequences in which the feedstock solids carbonaceousmaterial may participate, or perhaps to achieve desired molar ratios ofcarbon to other chemical components of the object select product gas. Ofcourse, this may be merely one example as to how carbon content may bestoichiometrically controlled, and should not be construed to limit themanner in which stoichiometric control may be applied to carbon contentconsistent with the principles described herein. Additional examples ofcontrolling carbon content may include adding carbon, adding carbonmonoxide, adding flue gas, adding pressurized flue gas, adding preheatedflue gas, adding an incompletely pyrolytically decomposed carbonaceousmaterial, adding an incompletely reformed carbonaceous material, addingat least some select product gas, adding at least some wet selectproduct gas, and adding at least some dry select product gas. Moreover,a stoichiometrically objectivistic adjustment compensator in variousembodiments of course may include a stoichiometrically objectivisticcarbon adjustment compensator.

Affirmatively establishing a stoichiometrically objectivistic chemicenvironment in some embodiments perhaps may involve simply varying aninput feedstock solids carbonaceous material, perhaps as describedelsewhere herein. Similarly, such establishing perhaps may involvesimply varying an output select product gas, as in perhaps varying theselect product gas qualities perhaps described elsewhere herein.Variations of input and output in this manner of course may vary therelationships among the input and output materials, perhaps creatingsuitable opportunity for application of the stoichiometric principlesdiscussed herein.

In some embodiments, affirmatively establishing a stoichiometricallyobjectivistic chemic environment may involve selecting a product gas tooutput, evaluating a feedstock solids carbonaceous material input, anddetermining a chemical reaction sequence appropriate to yield the selectproduct gas from the feedstock solids carbonaceous material. Evaluatinga feedstock solids carbonaceous material of course may employ astoichiometric evaluation, for example such as identifying proportions,quantities, and chemistry of constituent components of the feedstocksolid carbonaceous material, perhaps even as may be in relation topossible chemical reaction sequences appropriate to yield the selectproduct gas. A suitable evaluation system may be employed, for examplesuch as a chemistry sensor, a temperature sensor, a pressure sensor, amaterials composition sensor, a carbon monoxide sensor, a carbon dioxidesensor, a hydrogen sensor, a nitrogen sensor, a gas chromatograph, amass spectrometer, or the like. Moreover, embodiments further mayinvolve supplying chemical reactants on a stoichiometric basis, forexample perhaps as in sufficient to satisfy the molar ratios of achemical reaction sequence, sufficient to substantially completelychemically react the feedstock solids carbonaceous material, sufficientto produce a high output of select product gas, sufficient to temporallyaccelerate said chemical reaction sequence, or perhaps to effect otherstoichiometrically objectivistic considerations. Supply of such chemicalreactants of course may be effected with an appropriatestoichiometrically objectivistic chemical reactant input, for exampleperhaps a molar ratio input, a feedstock conversion input, a high outputselect product gas input, a catalyst input, or the like.

A flue gas in various embodiments perhaps may be utilized toaffirmatively establish a stoichiometrically objectivistic chemicenvironment. For example, interaction of the flue gas with the chemicenvironment may create stoichiometrically objectivistic conditions, forexample as wherein carbon content within a flue gas may contribute tostoichiometrically adjusting carbon levels within the chemicenvironment. Of course, this example simply may be illustrative of thestoichiometric properties of flue gas, and a flue gas may facilitateaffirmative establishment of a stoichiometrically objectivistic chemicenvironment in other manners. Moreover, the modalities by which suchflue gas may be stoichiometrically utilized may be consistent withprinciples described elsewhere herein. For example, a flue gas may bepressurized, perhaps to at least 80 psi. A flue gas may be preheated,perhaps to temperatures appropriate for a given processing stage such asat least 125° F., at least 135° F., at least 300° F., at least 600° F.,or at least 1,640° F. A flue gas may be recycled, perhaps includingrecycling to a pretreatment area, recycling to a pyrolysis chamber,recycling to a multiple coil carbonaceous reformation vessel, recyclingto a preliminary reformation coil of a multiple coil carbonaceousreformation vessel, recycling to a secondary reformation coil of amultiple coil carbonaceous reformation vessel, or recycling to atertiary coil of a multiple coil carbonaceous reformation vessel.Moreover, the stoichiometric use of a flue gas may be considered toaffect at least one process determinative parameter, perhaps asdescribed elsewhere herein, perhaps such as by raising a temperature,maintaining a pressure, raising a pressure, chemically reacting,temporally accelerating a chemical reaction sequence, displacing atleast some oxygen content from a feedstock solids carbonaceous material,displacing at least some water content from a feedstock solidscarbonaceous material, affirmatively establishing a stoichiometricallyobjectivistic chemic environment for said feedstock solids carbonaceousmaterial, and stoichiometrically controlling carbon content. Of course,the stoichiometric use of a flue gas may be effected by a suitable fluegas injector, consistent with the principles described herein.

In various embodiments, affirmatively establishing a stoichiometricallyobjectivistic chemic environment may include adding process beneficialmaterials and purging process superfluous materials. Adding processbeneficial materials perhaps may simply involve adding materials to aprocess environment tending to benefit stoichiometric conditions, forexample such as supplying materials to balance quantities in proportionto the molar ratios of a chemical reaction sequence or perhaps addingmaterials to induce or catalyze such chemical reaction sequences.Examples of process beneficial materials may include but may not belimited to carbon, hydrogen, carbon monoxide, water, preheated water, anegatively electrostatically enhanced water species, steam, negativelyelectrostatically enhanced steam, select product gas, wet select productgas, and dry select product gas. Similarly, purging process superfluousmaterials perhaps may simply involve removing materials superfluous, orperhaps even deleterious, to stoichiometric conditions, perhaps such ascontaminants or even excesses of process materials that perhaps may bebetter utilized through recycling. Examples of purging processsuperfluous materials may include but may not be limited to purgingoxygen, purging nitrogen, or perhaps even oxidizing metals andelectrostatically attracting such oxidized metals. Of course, suchadding and purging may be accomplished by any suitable input or purgeconsistent with the principles described herein.

Some embodiments may involve affirmatively establishing astoichiometrically objectivistic chemic environment by using recycling,perhaps as described elsewhere herein. The stoichiometric principles insuch embodiments may be the same as have been described, with perhapsutilized materials simply being recycled materials appropriatelyreturned from various areas of a solid carbonaceous materials gasifiersystem.

Affirmatively establishing a stoichiometrically objectivistic chemicenvironment in certain embodiments may include sensing at least oneprocess conditions and dynamically adjusting at least one processdeterminative parameter, perhaps as described elsewhere herein. Suchestablishing in some embodiments also may include evaluating a feedstocksolids carbonaceous material and responsively dynamically adjusting atleast one process determinative parameter, again perhaps as describedelsewhere herein. In some embodiments, affirmatively establishing astoichiometrically objectivistic chemic environment may involve removingwater from a feedstock solids carbonaceous material at a water criticalpass through, which perhaps may be a critical temperature and pressurefor a given feedstock solids carbonaceous material at which water maypass out of the feedstock.

Certain embodiments may affirmatively establish a stoichiometricallyobjectivistic chemic environment in multiple stages. For example, suchestablishing may involve preheating a feedstock solids carbonaceousmaterial, controlling oxygen content within the feedstock, as perhapswith an oxygen displacement system, and pyrolytically decomposing thefeedstock solids carbonaceous material. Of course, this example may bemerely illustrative of how a stoichiometrically objectivistic chemicenvironment may be established in multiple stages, and should not beconstrued to limit the manner in which such multiple stage establishmentmay be effected.

Various embodiments may involve affecting processing within a solidcarbonaceous materials gasifier system with negatively electrostaticallyenhanced water species. For example, embodiments may include injectingnegatively electrostatically enhanced water species into a gasifierprocess flow path, or perhaps even gasifier system components throughwhich the gasifier process flow path is routed, perhaps by using anegatively electrostatically enhanced water species injector, routing agasifier process flow path by a negatively electrostatically enhancedwater species injector, and the like. The injection of a negativelyelectrostatically enhanced water species in such a manner perhaps maybring it into contact with carbonaceous materials entrained in agasifier process flow path, including for example perhaps at apretreatment area, a pyrolysis chamber, a multiple coil carbonaceousreformation vessel, a select product gas components scrubber, and thelike.

In some embodiments, a negatively electrostatically enhanced waterspecies may include an aqueous solution having a net negative charge, asperhaps having a negatively charged species content exceeding acontaminant background demand for the negatively charged speciescontent. Examples of a negatively electrostatically enhanced waterspecies in various embodiments may include an aqueous solutioncontaining saturated hydrogen peroxide and negatively charged oxygen, anaqueous solution containing saturated hydrogen peroxide and singletmolecular oxygen, an aqueous solution containing saturated hydrogenperoxide and hydroxide, an aqueous solution containing saturatedhydrogen peroxide and hydroxide radicals, an aqueous solution containinglong-chain negatively charged oxygen species, a peroxyl activatedaqueous solution, a nitroxyl activated aqueous solution, an oxygenatedaqueous solution, an ionized oxygen vapor aqueous solution, and thelike.

A negatively electrostatically enhanced water species in someembodiments perhaps may be preheated. Of course, preheating may beaccomplished in any suitable manner consistent with the principlesdescribed herein, for example perhaps using a suitable preheater,perhaps such as a combustive burner or electric heater. In certainembodiments, a preheater for a negatively electrostatically enhancedwater species perhaps may be a gasifier system process enclosure, suchas perhaps a pyrolysis chamber enclosure, a multiple coil carbonaceousreformation vessel enclosure, or perhaps even a box furnace enclosure(26) (FIGS. 1; 2; 13; 14). Moreover, preheating a negativelyelectrostatically enhanced water species of course may generate steam,perhaps negatively electrostatically enhanced steam.

The manner in which a negatively electrostatically enhanced waterspecies may affect processing within a solid carbonaceous materialsgasifier system may be selected to achieve a desired result, for exampleperhaps to increase the purity of a select product gas, increase the BTUvalue of a select product gas, minimize contaminants in a select productgas, and the like. Such desired results may be considered to be, forexample, injection products following the injection of a negativelyelectrostatically enhanced water species into a gasifier process flowpath. Moreover, the use of a negatively electrostatically enhanced waterspecies in this way perhaps even may be considered as one example ofdynamically adjusting a process determinative parameter. For example,affecting processing perhaps may involve chemically reacting anegatively electrostatically enhanced water species, as perhaps withcarbonaceous materials entrained in a gasifier process flow path. Insuch embodiments, the negatively electrostatically enhanced waterspecies simply may be chemical reactant participating one or morechemical reaction sequences with the carbonaceous material, for exampleas to perhaps produce hydrogen select product gas components, producecarbon select product gas components, decrease hydrocarbon contaminants,increase carbon monoxide, increase hydrogen gas, and the like. Moreover,utilizing a negatively electrostatically enhanced water species as achemical reactant perhaps may involve using it as catalyst, for exampleperhaps to temporally accelerate one or more chemical reactionsequences, or perhaps even to maximize the yield of one or more chemicalreaction sequences. In some embodiments, such uses of a negativelyelectrostatically enhanced water species even perhaps may be part ofaffirmatively establishing a stoichiometrically objectivistic chemicenvironment and stoichiometrically controlling carbon content. Someembodiments may involve coactively utilizing a negativelyelectrostatically enhanced water species with other process materials,for example perhaps injecting a negatively electrostatically enhancedcoactively with a flue gas.

Accordingly, negatively electrostatically enhanced water species may beuse in a variety of processing application within a solid carbonaceousmaterials gasifier system. In embodiments having specific inputfeedstock solids carbonaceous materials chemistry, adjustable volumes ofselected negatively electrostatically enhanced water species may beprovided, for example such as more reactive ionized oxygen water, andperhaps may be injected and perhaps vapor released into a gasifierprocess flow path, as perhaps into one or more carbonaceous reformationcoils of a multiple coil carbonaceous reformation vessel. This perhapsmay also cause additional thermal steam vapor-cavitation turbulencereactions. The presence of a negatively electrostatically enhanced waterspecies in the gasifier process flow path may provide much faster andmore complete carbon conversion and steam reformation reactions tooccur, for example such as within a pyrolysis chamber. Additionally,embodiments may have the capability to dynamically adjust processdeterminative parameters that may achieve a generation of optimum selectproduct gas production energy ratios, decrease of CO₂ contamination, andincrease or adjustment of desired higher energy output ratios ofhydrogen and carbon monoxide, perhaps including the capability ofprocess adjustments to yield higher output percentage fractions ofmethane content.

Moreover, negatively electrostatically enhanced water species may berecycled, perhaps to achieve nearly 100% recycling, as perhaps in aclosed loop process within a solid carbonaceous materials gasifiersystem, and as to perhaps even exceed an environmental standard forrecycling such a negatively electrostatically enhanced water species. Invarious embodiments, such recycled negatively electrostatically enhancedwater species may be a recovered contaminant solubilization substancefrom a select product gas components scrubber. Through recycling,negatively electrostatically enhanced water species, such as perhapsionized and perhaps peroxide saturated water, may be constantly providedto meet various process water control volume requirements within thesolid carbonaceous materials gasifier system. For example, recycle usesof negatively electrostatically enhanced water species may includerecycling to a pretreatment area, recycling to a pyrolysis chamber,recycling to a multiple coil carbonaceous reformation vessel,solubilizing a flue gas in a recycled negatively electrostaticallyenhanced water species, re-solubilizing at least one contaminant in arecycled negatively electrostatically enhanced water species,regenerating a negatively electrostatically enhanced water species, andgenerating steam from a negatively electrostatically enhanced waterspecies

Within the select product gas components scrubber, accelerated oxidizingand reducing negatively electrostatically enhanced water species recycleapplications, perhaps as in-situ chemistry applications, along withchilled water condensing, perhaps may be applied which may provide forthe isolation of items such as soluble tar, phenols, organic hydrocarbonvapors, particulate contaminants, and perhaps even soluble CO₂ andsulfur removals from various select product gas components, perhaps toproduce a scrubbed select product gas. Recycled negativelyelectrostatically enhanced water species, as perhaps from a selectproduct gas components scrubber, also may be used to scrub flue gas tomaintain flue exhaust gas environmental air quality at or near zerodischarge compliance, whenever flue gas may be discharged into theatmosphere.

A negatively electrostatically enhanced water species may be generatedin various embodiments perhaps by a negatively electrostaticallyenhanced water species generation unit. Such a unit perhaps even may beintegrated into a solid carbonaceous materials gasifier system, such asperhaps to permit on-site generation of negatively electrostaticallyenhanced water species and direct communication with a gasifier processflow path. For example, such a unit may be joined to a negativelyelectrostatically enhanced water species injector of a select productgas components scrubber. In embodiments, an initial generation ofperhaps ionized oxygen vapors may take place within a negativelyelectrostatically enhanced water species generation unit, perhaps a gasionization cylindrical system (31) such as shown in FIGS. 1; 2; 10; 11;16. This may provide an efficient and perhaps high rate production ofreactive and activated oxygen and ionized vapors. Such a unit in someembodiments may be a VIP™ vapor ion plasma generator, although suchshould use not to be taken to limit the inventive technology only tosuch embodiments. The use of a negatively electrostatically enhancedwater species generation unit, again perhaps such as a VIP™, may referto the production of ionized oxygen, associated peroxyl vapor gas ions,or the like. Such a negatively electrostatically enhanced water speciesgeneration unit may provide an efficient contaminant solubilizationsubstance treatment unit. The components perhaps may be optimized togenerate a plethora of highly reactive singlet oxygen species fromoxygen in air. Such may occur under circumstances also encouragingsecondary recombination with water, perhaps water vapor or steam vapor,such as to perhaps produce additional hydroxide and hydrogen peroxidegas vapor ions. In various embodiments, such as shown in FIGS. 10 & 11,a negatively electrostatically enhanced water species generation unitmay include, but may not require, elements as follows:

-   -   element (84) LECTRON Power Supply Module    -   element (85) LECTRON “Plasma (Variable) Emission” Generator    -   element (86) (Air-Cooled) Aluminum “Spectral-Physics” Ionization        Reactor    -   element (87) Primary Electronic power Supply Module    -   element (88) AIR-INTAKE (1.5″ Wide “Ring” Intake Air Filter        (Atmospheric Nitrogen/Oxygen Air as the Ambient Treatment        Source)    -   element (89) VIP-™ Generated Vapor Ion (Out-Take) Delivery Port    -   element (90) O₂/O₂/0-0/e/OH Gas Vapor Ions (also generates H₂O₂        & Intermediate “Reaction By-Products” of Above)    -   element (91) Pump Injection (“Vortex Eduction”) Into        Contaminated Water Flow    -   element (92) 45 degree Return Line Rotation    -   element (93) Recirculation Flow Scrubber (Vapor Spray) “Ionized        H₂O” contact tank    -   element (94) 3″ Dia. Pipe Flange Connection    -   element (95) 3″ Cross    -   element (96) 3″×2″ Reducing Tee    -   element (97) 3″ Valve    -   element (98) Drain    -   element (99) (Optimal) Dual System Treatment Modules    -   element (100) Flow to Process Treatment “Entrained-Flow        Gasifier” Equipment    -   element (101) 7.5 H.P. Venturi Injector Pumps (#316 Stainless        Steel Construction)    -   element (102) (4) VIP-™ Hi-Intensity “Ionized Oxygen” Generators    -   element (103) (4) Venturi Injectors—All 1″ Thread Connections    -   element (104) 1″ Dia. Stainless Steel (Each Venturi) Return        Piping

The generation of negatively electrostatically enhanced water speciesmay involve the use of singlet oxygen. This species of ionized oxygenmay be referred to in academic and published literature as thesuperoxide ion. Superoxide vapor ions perhaps may be employed since theymay be capable of strong oxidation or reduction reactions. Inembodiments, the superoxide ion may be produced in conjunction with asolid carbonaceous materials gasifier system perhaps to generatenegatively electrostatically enhanced water species, for example perhapsby combining a singlet oxygen species with water and generatinglong-chain negatively charged oxygen species, hydroxide, hydrogenperoxide, peroxyl, or the like. Moreover, such use of singlet oxygen mayproduce multiple beneficial processing effects. For example, negativelyelectrostatically enhanced water species produced from such singletoxygen may be utilized in carbonaceous reformation, as perhaps inthermal conversion, steam reformation, devolatilization and the like,perhaps within one or more reformation coils of a multiple coilcarbonaceous reformation vessel. Further examples may include therelease of negatively electrostatically enhanced water species, perhapsHO₂ ⁻ peroxyl scavenger and highly reactive steam vapor ions, within andthroughout a multiple coil carbonaceous reformation vessel in certainembodiments.

Table 2 illustrates what may be representative of some of the majorchemical reaction sequences whereby various negative electrostaticenhancement species, perhaps for use in generating a negativelyelectrostatically enhanced water species and perhaps including singletmolecular oxygen ions, may be formed. Of course these are merelyillustrative of such chemical reaction sequences and should not beconstrued to limit the inventive technology thereby. Table 2 may show areaction of atmospheric oxygen, under the influence of short-wavelengthultraviolet energy (“UV”) and a magnetic field (referenced by thesymbols “MAG. E”) as it may form a polarized or magnetic oxygenmolecule, and thence may dissociate into singlet molecular oxygen ionspecies (also known as Superoxide Tons), which may be highly reactive.Table 2 also may show the formation of ozone, which in itself may beextremely reactive, and which also may dissociate to form singletmolecular oxygen ions. Table 2 also may show that the singlet molecularoxygen gas may further react with water vapor and may form hydrogenperoxide and perhaps hydroxide radicals. As illustrated by Table 2, theionized oxygen may also react to form various combinations of hydrogenperoxide and/or hydroxide in water.

TABLE 2 VIP ™ Process Reaction Chemistry Sequence ProducingIonized/Oxygenated Water

NOTE: EXCESS SINGLET & CHAINED SINGLET OXYGEN IONS REMAIN SATURATED INH₂O, PROVIDING A RESIDUAL OF OXIDIZING & COAGULATIVE REACTION AGENTS.VIP ™ = Vapor Ion Plasma

Various embodiments may involve producing a flue gas within a solidcarbonaceous materials gasifier system, for example perhaps within aflue gas generation zone of the gasifier system. Such a flue gasgeneration zone may include for example a gasifier system processenclosure, perhaps as wherein a combustive burner may produce flue gasand may be enclosed within a combustive heat enclosure to heat part of agasifier process flow path. Moreover, such produced flue gas inembodiments may be recycled to other areas of the gasifier system,perhaps such as to a pretreatment area, a pyrolysis chamber, a multiplecoil carbonaceous reformation vessel, a preliminary reformation coil ofa multiple coil carbonaceous reformation vessel, a secondary reformationcoil of a carbonaceous reformation vessel, a tertiary reformation coilof a carbonaceous reformation vessel, or the like. Such recycling mayinvolve routing recycled flue gas via a flue gas recycle path appendedto the flue gas generation zone, perhaps to a flue gas recycle input ofa gasifier process flow path, wherein the recycled flue gas perhaps maybe injected into the gasifier process flow path as with a flue gasinjector.

Recycled flue gas of course may be used in any appropriate mannerconsistent with the principles described herein, such as perhaps toaffect a process determinative parameter of the gasifier system. Forexample, affecting a process determinative parameter may include raisinga temperature, wherein a flue gas injector may be configured as aheater. Affecting a process determinative parameter also may includemaintaining or raising a pressure, in which a flue gas injector may beconfigured as a pressure system. Affecting a process determinativeparameter further may include chemically reacting a flue gas ortemporally accelerating a chemical reaction sequence with a flue gas, inwhich a flue gas injector may be configured as a chemical reactantinjector or perhaps even a catalyst injector as appropriate. Affecting aprocess determinative parameter also may include displacing oxygencontent or water content from a feedstock solids carbonaceous material,in which a flue gas injector may be configured as an oxygen displacementsystem or a water displacement system, respectively. Affecting a processdeterminative parameter also may involve affirmatively establishing astoichiometrically objectivistic chemic environment andstoichiometrically controlling carbon content, in which a flue gasinjector may be configured as a stoichiometrically objectivistic carboncompensator. Moreover, pressurizing a flue gas may be for exampleperhaps to at least 80 psi, and preheating a flue gas may be for exampleto at least 125° F., at least 135° F., at least 300° F., at least 600°F., or even at least 1,640° F.

Various embodiments may involve selectively adjusting a process flowrate through a gasifier process flow path, for example perhaps with aselectively adjustable flow rate regulator. Adjusting such a processflow rate for example may include adjusting the flow characteristics ofcarbonaceous materials entrained in the gasifier process flow path. Oneexample in various embodiments may involve regulating a pressure tovelocity ratio for a process flow through a multiple coil carbonaceousreformation vessel, such as maintaining a pressure of at least 80 psi,maintaining a flow rate of at least 5,000 feet per minute, or perhapsmaintaining a Reynolds Number value of at least 20,000. Another examplein various embodiments may involve dominatively pyrolyticallydecomposing a feedstock solids carbonaceous material and acceleratedlycarbonaceously reforming the dominatively pyrolytically decomposedfeedstock solids carbonaceous material, for example as wherein thefeedstock solid carbonaceous material may be retained within a pyrolysischamber for greater than about 4 minutes, and wherein the pyrolyticallydecomposed carbonaceous material may be carbonaceously reformed fromabout 4 seconds to about 10 seconds.

In some embodiments, selectively adjusting a process flow rate may beaccomplished with a venturi injector, perhaps to regulate a process flowrate. A venturi injector perhaps may regulate a process flow byutilizing Bernoulli effects achieved through a tube of variedconstriction, perhaps configured in the form of a venturi. In someembodiments, a venturi injector (17) (FIGS. 1; 2; 8; 9; 14) may providea cavitation or other high-mix turbulence unit, perhaps point source,that may contribute to increasing higher efficiency steam reformationcontact, perhaps with pass-through carbon particulate material. Theventuri injector design (17) (FIGS. 1; 2) illustrated in FIGS. 8; 9 mayinclude an input, perhaps a steam input, a negatively electrostaticallyenhanced water species input, or a select product gas input, such as atan injection port (51) (FIGS. 1; 2), whereby complete rotational flowturbulent mixing of an input substance may be provided. For example,reformation coil reaction rates, perhaps as in a multiple coilcarbonaceous reformation vessel, may be accelerated with the reactantsmixing or cavitationally impinging upon one another. Substantial mixing,including perhaps greater than 90% mix-atomization turbulence andperhaps even near 100% mix-atomization turbulence, perhaps may alsooccur in the process flow passing through the venturi injector throatbody. Also, the exit port body of the venturi injector perhaps may befitted with a stop-block ring, which may create an additional zone ofintense and secondary turbulence, perhaps by impeding the process flow.

An injection port (51) may be disposed on a venturi injector (17) in anysuitable configuration, for example perhaps tangentially positioned atthe throat of the venturi injector (17). Moreover, an injection port(51) of course may be configured to inject any suitable substance intothe venturi injector (17), and of course consequently venturi inject thesubstance into a gasifier process flow path, consistent with theprinciples described herein. For example, an injection port (51) invarious embodiments may include a flue gas injection port, a pressurizedflue gas injection port, a preheated flue gas injection port, a recycledflue gas injection port, a water injection port, a preheated waterinjection port, a recycled water injection port, a negativelyelectrostatically enhanced water species injection port, a preheatednegatively electrostatically enhanced water species injection port, arecycled negatively electrostatically enhanced water species injectionport, a steam injection port, a recycled steam injection port, anegatively electrostatically enhanced steam injection port, a recyclednegatively electrostatically enhanced steam injection port, a selectproduct gas injection port, a wet select product gas injection port, adry select product gas injection port, and a recycled select product gasinjection port.

Utilization of a venturi injector (17) (FIGS. 1; 2; 8; 9; 14) may beprovided at any suitable location or locations of a gasifier processflow path to regulate flow rates or characteristics, perhaps such asshown for some embodiments in FIGS. 2; 8; 9; 14. These may be connectedwith one unit per each of the reformation coils of a multiple coilcarbonaceous reformation vessel, as perhaps may be installed in adownward process flow side of each reformation coil, or in othergasifier process flow path control locations. Alternate venturi injectorpositions perhaps may be provided as additional dynamically adjustableprocess determinative parameters. The position of the venturi injectorsmay be altered to provide additional high levels of process flowefficiencies, such as perhaps when venturi injectors (17) may beconnected one each on the outlet side of each of the cyclones (20)(FIGS. 1; 2; 14). The dynamically adjustable process determinativeparameters that may define the specific, and perhaps optimal, number ofventuri injectors (17), and that may be installed within the overalllength of a reformation coil-cyclone closed process loop, may also be afunction of identifying the available energy and carbon content of theinput feedstock solids carbonaceous material. In some embodiments, forexample, it may be that no more than four venturi injectors (17) mayneed to be installed, perhaps because total pressure drop, or headlosses, may increase proportionally. A reformation coil near minimumpressure of 80 psi to 100 psi, along with a high velocity operatingthroughput process flow, of perhaps a minimum velocity of about 5,000feet per minute through the entire reformation coil-cyclone assembly,perhaps may need to be maintained, as the pressure to velocity ratio mayrepresent an operational control variable in some embodiments. The exactconfiguration and number of installed venturi injectors (17) perhaps maybe determined accordingly, so that the reformation coil pressure andprocess flow velocities perhaps may be constantly maintained at adesired level.

In some embodiments, a venturi injector (17) may include an injectionport, through which the provision of side-stream negativelyelectrostatically enhanced water species injection, such as perhapshydrogen peroxide saturated water, may induce an excited steam statereaction activity perhaps throughout the length of the reformation coilsof a multiple coil carbonaceous reformation vessel. It perhaps may alsothereby accelerate carbon dioxide destruction reactions and perhaps mayeven substantially increase carbon monoxide and hydrogen generation.This may be understood by the following reaction equation sequence,Table 3:

TABLE 3

The scientific basis for this CO₂ depletion, as may occur within thegasifier process flow routed through the reformation coils of a multiplecoil carbonaceous reformation vessel, may be contingent upon thegeneration of singlet molecular oxygen (O₂ ⁻), such as might be producedfor combination with water to produce a negatively electrostaticallyenhanced water species, such as hydrogen peroxide saturated water. Thismay be as shown in Table 3. When singlet oxygen, perhaps peroxidesaturated water, may be injected into the reformation coils (19) (FIGS.1; 2; 3; 4; 14) of a multiple coil carbonaceous reformation vessel, itmay convert to a released and perhaps excited state HO₂ ⁻ peroxyl ion,which may react with the gasifier process flow stream. Embodiments maysimilarly produce a HO₂ ⁻ vapor ion, and this may be similarly injectedinto the reformation process.

In certain embodiments, flow through three or four connected venturiinjectors (17) (FIGS. 1; 2; 8; 9; 14) may range at a pressure frombetween about 80 psi to about 100 psi, and the pressure may bemaintained throughout areas such as the reformation coils of a multiplecoil carbonaceous reformation vessel (19) (FIGS. 1; 2; 3; 4; 14),perhaps through associated connected cyclones such as cyclones (20),(22), and (23) respectively (FIGS. 1; 2; 3; 4; 14). In embodiments, thispressure may perhaps overcome the total accumulated back-pressure or thesum of the head losses within a multiple coil carbonaceous reformationvessel, or perhaps be able to sustain higher and perhaps optimumgasifier process velocities such as not less than about 5,000 feet perminute throughout the vessel. Perhaps even at, or above, an appropriatevelocity, high energy Reynolds Numbers of 20,000+ may be achieved toperhaps ensure that tars, phenols, hydrocarbons and other debrisinorganics or particulates may not plate-out or begin to agglomeratewithin the reformation coil components. Carbonaceous materials, perhapsparticulates or atomized char organic particles, may also thoroughlyreact in the gasifier process flow, as perhaps with high pressure steamgenerated such as within the reformation coils, perhaps with watercarry-through or perhaps a negatively electrostatically enhanced waterspecies being the source for the steam. Embodiments may also producehighly efficient carbon shift and conversion reactions. In embodiments,total reformation time within a multiple coil carbonaceous reformationvessel, perhaps including cyclone retention times, may be engineered tobe process maintained, perhaps even in the 4 second to 10 second range,and perhaps as dependent upon the daily tonnage of raw feedstock solidscarbonaceous materials throughput that may be desired. Computerizedautomation, perhaps coupled with continuous read mass spectrometer andgas chromatograph online instrumentation, may be included to providecontrol functions that may readily determine dynamic adjustments toperhaps optimize process determinative parameters, perhaps such asprocess flow velocities, process flow pressures, and/or perhaps ReynoldsNumber operational set-points. This control procedure perhaps may ensurethat clean select product gas, perhaps with minimal CO₂ and hydrocarbonresidual contamination, may be produced at high BTU energy value.Controlled molar ratios of select product gas components, for examplesuch as at least 1:1 molar ratios of carbon monoxide to hydrogen andperhaps up to approximately 20:1 molar ratios of carbon monoxide tohydrogen, may be produced in the select product gas and perhaps may beconsistently held, perhaps with fractional or even no substantial carbondioxide content, nitrogen oxide content, or sulfur oxide contentcontaminants present in the generated select product gas.

Using the principles described herein, embodiments may involve creatinga high energy content select product gas. For example, creating such ahigh energy content select product gas may involve increasing its BTUvalue. Processing steps tending to increase BTU value may be employed,perhaps in a manner to create a higher BTU value select product gas ascompared to processing steps using conventional gasification techniques.Accordingly, embodiments may involve the production of a select productgas having a BTU value of at least 250 BTU per standard cubic foot,having a BTU value from about 250 BTU per standard cubic foot to about750 BTU per standard cubic foot, having a BTU value from about 350 BTUper standard cubic foot to about 750 BTU per standard cubic foot, havinga BTU value from about 450 BTU per standard cubic foot to about 750 BTUper standard cubic foot, having a BTU value from about 550 BTU perstandard cubic foot to about 750 BTU per standard cubic foot, and havinga BTU value from about 650 BTU per standard cubic foot to about 750 BTUper standard cubic foot. In various embodiments, varied inputs offeedstock solids carbonaceous materials may nevertheless result inconsistent BTU values for produced select product gas, with perhaps theamount of produced select product gas varying in quantity proportion tothe BTU value of the input feedstock carbonaceous material.

Moreover, creating a high energy content select product gas may involveincreasing the purity of a select product gas. Again, processing stepstending to increase purity may be employed, perhaps in a manner toincrease purity as compared to processing steps using conventionalgasification techniques. Purifying a select product gas may involve, forexample, isolating or perhaps removing one or more contaminants. Forexample, purifying a select product gas in various embodiments mayinvolve minimizing nitrogen oxide content of a select product gas,minimizing silicon oxide content of a select product gas, minimizingcarbon dioxide content of a select product gas, minimizing sulfurcontent of a select product gas, minimizing organic vapor content of aselect product gas, and minimizing metal content of a select productgas.

The processing steps used to create a high energy content select productgas may be as have been described herein, and for example may includebut may not be limited to processing with a negatively electrostaticallyenhanced water species, processing with a recycled select product gas,processing with negatively electrostatically enhanced steam, processingwith a flue gas, varying a process retention time, processing in atleast a preliminary reformation coil and a secondary reformation coil,recycling an incompletely pyrolytically decomposed carbonaceousmaterial, and recycling an incompletely reformed carbonaceous material.

Also using the principles described herein, embodiments may involvepredetermining a desired select product gas for output. Suchpredetermining may involve consistently outputting a desiredpredetermined select product gas from varied input feedstock solidscarbonaceous materials, as perhaps wherein one or more processing stageswithin a solid carbonaceous materials gasifier system may compensate forvariations among input feedstock solids carbonaceous materials. Forexample, predetermining in various embodiments may involve affirmativelyestablishing a stoichiometrically objectivistic chemic environment,stoichiometrically controlling carbon content, dynamically adjusting atleast one process determinative parameter within a solid carbonaceousmaterials gasifier system, or the like. Such adjustments perhaps mayconfer a high degree of control over the characteristics of apredetermined select product gas. For example, a predetermined selectproduct gas in various embodiments may include a variable carbonmonoxide content select product gas, a primarily carbon monoxide selectproduct gas, a variable hydrogen content select product gas, a primarilyhydrogen gas select product gas, a variable methane content selectproduct gas, a primarily methane select product gas, a select productgas of primarily carbon monoxide and hydrogen gas and methane, acontrolled molar ratio select product gas, a controlled molar ratioselect product gas having a hydrogen gas to carbon monoxide molar ratioof from 1:1 up to 20:1 by volume, a controlled molar ratio selectproduct gas having a hydrogen gas to carbon monoxide molar ratio of atleast about 1:1, a controlled molar ratio select product gas having ahydrogen gas to carbon monoxide molar ratio of at least about 2:1, acontrolled molar ratio select product gas having a hydrogen gas tocarbon monoxide molar ratio of at least about 3:1, a controlled molarratio select product gas having a hydrogen gas to carbon monoxide molarratio of at least about 5:1, a controlled molar ratio select product gashaving a hydrogen gas to carbon monoxide molar ratio of at least about10:1, a controlled molar ratio select product gas having a hydrogen gasto carbon monoxide molar ratio from at least about 1:1 to about 20:1, acontrolled molar ratio select product gas having a hydrogen gas tocarbon monoxide molar ratio from at least about 2:1 to about 20:1, acontrolled molar ratio select product gas having a hydrogen gas tocarbon monoxide molar ratio from at least about 3:1 to about 20:1, acontrolled molar ratio select product gas having a hydrogen gas tocarbon monoxide molar ratio from at least about 5:1 to about 20:1, acontrolled molar ratio select product gas having a hydrogen gas tocarbon monoxide molar ratio from at least about 10:1 to about 20:1, aproducer gas, and a synthesis gas. Moreover, a select product gas invarious embodiments may include a base stock, as wherein the producedselect product gas may be used as a basis for post-gasifier systemapplications, for example as stock for the production of additionalsubstances. Accordingly, a select product gas in various embodimentsperhaps may include a variable chemistry base stock, a liquid fuel basestock, a methanol base stock, an ethanol base stock, a refinery dieselbase stock, a biodiesel base stock, a dimethyl-ether base stock, a mixedalcohols base stock, an electric power generation base stock, or anatural gas equivalent energy value base stock.

Further using the principles described herein, embodiments may involveproducing a high yield select product gas, perhaps even exceeding atypical yield of conventional gasification processes for produced selectproduct gas from a given input feedstock solids carbonaceous material.For example, such high yields may involve converting greater than about95% of the feedstock mass of a feedstock solids carbonaceous material toselect product gas, converting greater than about 97% of the feedstockmass of a feedstock solids carbonaceous material to select product gas,converting greater than about 98% of the feedstock mass of a feedstocksolids carbonaceous material to select product gas, outputting at leastabout 30,000 standard cubic feet of select product gas per ton offeedstock solids carbonaceous material, or perhaps achieving a carbonconversion efficiency of between 75% and 95% of carbon content in afeedstock solids carbonaceous material converted to select product gas.Moreover, a high yield in certain embodiments may involve substantiallyexhausting a carbon content of an input feedstock solids carbonaceousmaterial.

In some embodiments, the inventive technology described herein perhapsmay be configured in a modular and compact form, perhaps that mayprovide an autonomous and uncomplicated select product gas generationtechnology that may allow for selected conditions operational capabilityand that may produce a very high purity and high energy select productgas from a variety of input feedstock solids carbonaceous materials,perhaps even virtually any type of organic biomass, coal input or othercarbonaceous raw material. Of course, such modularity merely may be oneaspect of the inventive technology, and should not be construed to limitthe inventive technology only to modular embodiments. Predeterminedadjustments in operating process retention times, gas velocitypressures, negatively electrostatically enhanced water species injectioncontrol rates, recycled select product gas injection parameters, andflue gas injection parameters may be included to further provide for thegenerated select product gas final output chemistry to be tuned, forexample perhaps as may be related to producing large, perhapsuncontaminated volumes of secondary off-take commodities, such as liquidfuels, electricity generation, hydrogen gas, and the like. Set-pointoperational parameters may be included, such as progressive control ofdevolatilization temperature, adjustable gas velocity and reaction time,variable water, perhaps steam, negative electrostatic enhancementchemistry additions, or basic steam reformation operational energybalance capabilities. Environmental beyond-compliance discharge orperhaps even zero discharge may be maintained in some embodiments,perhaps with exhaust flue gases being internally recycled. Inembodiments, a negatively electrostatically enhanced water speciestreatment system may be included to provide the possibility for a highpercentage, or perhaps even 100%, recycle and reuse of highly purifiedwater to be constantly returned back into the process. In embodiments,small volumes of process residual or system drain excess water may berelatively pure and perhaps may be flash evaporated with application ofsystem excess heat, with perhaps no discharge to the environment.Further, applied negatively electrostatically enhanced water processesmay be included perhaps to scrub and purify flue gas exhaust tracereleases, including if and when applicable to meet relevant air qualityemission control regulations. Embodiments even may provide one overalllow maintenance and simple operation system design that may beeconomically feasible for a variety of given applications.

Some embodiments perhaps may provide an entrained flow select productgas generation system. In some embodiments, process parameters may allowmany available and various kinds of carbonaceous wastes or commercialfeedstock materials, such as wood waste, garbage, sewage solids, manure,agricultural or other environmental biomass, shredded rubber tires,coal, and the like, perhaps all to be processed perhaps through onebasic platform design. In embodiments, energy may be released andrecovered as a produced select product gas, perhaps containing highcombustion ratios of adjustable content CO and H₂, perhaps along withsecondary by-product generation of water, carbon dioxide, and lighthydrocarbons that perhaps may be laced with volatile, but perhapscondensable, organic and inorganic additional, perhaps contaminant,compounds. Impurities perhaps may be removed within a secondary negativeelectrostatically enhanced water species scrubber section as well.

As an alternate to using coal as a commercially available feedstockmaterial (e.g., a feedstock perhaps with consistent carbon conversioncontent), there may be a variety of non-coal biomass resourcesavailable, perhaps being widely and demographically dispersed. These mayvary greatly in their heterogeneous chemical characteristics makeup.Embodiments of the inventive technology may provide a system applicationfor an adjustable broad spectrum, perhaps even near universal selectproduct gas generation process control design, and may further provide aperhaps operational, perhaps economic, perhaps efficient system thatperhaps may be completely capable of processing nearly any type of inputcarbonaceous feedstock and generating high energy select product gasoutput. Embodiments of the inventive technology also may be capable ofavailability throughout the world marketplace, and may providealternative select product gas availability to the world marketplace.

FIGS. 18 through 22 show a portable or “pod” embodiment of theinvention. As can be understood from the FIG. 18, this embodiment mayinclude a pod or isolated reactor unit (211). This isolated reactor unit(211) may be surrounded by a refractory area (212). The refractory area(212) may include a sealed refractory shroud (213). A feed (214) mayprovide material to the isolated reactor unit (211) as shown. Thematerial may then be acted upon in an upper pyrolysis deck (215) andperhaps subsequently a lower steam reformation deck (220). Each of thesedecks may actually be rotating carousel decks (216). These rotatingcarousel decks (216), may be aligned with a carousel drive shaft (217),which may be supported by an upper bearing support (218) and perhaps abottom oil seal pivot bearing (219). The entire isolated reactor unit(211) may be surrounded at least partially by a flue gas chamber (221).For reasons discussed earlier, ionized water nozzles or injectors (222)may be included as well. Spend material may fall into an ash drop (223),which may pass through an air lock valve (224), an ash auger (226), andultimately into an ash collection bin (227). The system may be driven bya gearbox drive (225).

To provide the input feed, and embodiment may include a feed section(229). The feed section (229) may provide material from a bunker pin orthe like. Perhaps through multiple venturi injectors (228) that eachpermit an adequate amount of pressure increase. The feed section (229)may be surrounded by a gas shroud chamber (230). This gas shroud chamber(230), allows passage of flue or product gas, which may permitpre-heating a feedstock material. As shown, material may pass into afeed plenum (231), which may act as a separator (232) to separate amotive agent such as a gas or the like from the feed material. The feedplenum (231), may have an access (233) through which a motive agent orthe like may pass in or out. As may be understood, in an instance wherethe motive agent is an agent such as flue gas, the excess gas may passout of the access (233) and return to the system for recycling or reuse.Similarly, the system may include a shroud flue gas output (235), whichmay permit flue gas output shroud gas for return to the system or thelike. This return may have various input locations, such as the venturiinjectors or other locations.

Further, the “pod” embodiment shown may include a raw feedstock input(237) such as from a feedstock bin or the like. This feedstock input(237) can accept an external source of material for appropriateprocessing.

FIG. 21 shows a similar system in a more generic understanding. As oneway providing compact processing, operations may include mechanicallypropelling at least one carbonaceous materials pyrolysis decompositionplatform. This carbonaceous materials pyrolysis decomposition platformsuch as the upper pyrolysis deck (215). Operations may also includemechanically propelling at least one pyrolytically decomposedcarbonaceous materials processor platform such as the lower steamreformation deck (220). These may be propelled by a mechanical gasifierdrive system (201). In fact both the decks may be platforms and thus thesystem may include a mechanically propelled carbonaceous materialspyrolysis decomposition platform (202) and a mechanically propelledpyrolytically decomposed carbonaceous materials processor platform(203). In this fashion the system can be considered as having aplurality of environment differentiated mechanically propelledpyrolytically decomposed carbonaceous materials processor platforms.

It should be understood that the type of mechanical propulsion used canvary. In one embodiment, the system may include rotating platforms. Asshown, there may be a rotating pyrolytically decomposed carbonaceousmaterials processor platform such as the upper pyrolysis deck (215), anda rotating a carbonaceous materials pyrolysis decomposition platform,such as the lower steam reformation deck (220). As may be understood, itmay be advantageous for embodiments to have the rotations be horizontalrotations, that is, in a perpendicular to gravity. In addition, it maybe advantageous to coordinate the rotation are other movements involved.In this way, the system may involve coordinated movement platforms orcoordinatively mechanically propelling items for appropriate processing.These coordinated movements may be synchronous and may even be driven bya single drive. Thus, the system may include synchronous duality ofmovement platforms, driven by a single mechanical gasifier drive system.As can be appreciated, by singularly driving both platforms, only onedrive system may be necessary. In addition, the platforms may rotate atidentical rates for one type of coordinated processing.

Processed material may be subjected to different environments as itsequences through the reactor. These environments may be differentiatedby any number of variables. As but some examples, the environments maybe differentiated by process factor variable such as: a process materialsize factor, a process temperature factor, a process duration factor, adifferentiated environment factor, a reactor electrostatic steam factor,a chemic environment factor, a water environment factor, a negativeelectrostatic charge water environment factor, a differentiated carboncontent factor, a differentiated oxygen content factor, a differentiatedflue gas content factor, a differentiated product gas factor, a recycledprocess material factor, among others. The platforms and even thegeneric processor can sequence and have different components as well.Processors may be: a variable temperature zone carbonaceous feedstockprocessor, a carbonaceous feedstock processor configured to establish atemperature from 125 degrees Fahrenheit to 135 degrees Fahrenheit, acarbonaceous feedstock processor configured to establish a temperaturefrom 135 degrees Fahrenheit to 300 degrees Fahrenheit, a carbonaceousfeedstock processor configured to establish a temperature from 300degrees Fahrenheit to 1,000 degrees Fahrenheit, a carbonaceous feedstockprocessor configured to establish a temperature from 1,000 degreesFahrenheit to 1,640 degrees Fahrenheit, and a carbonaceous feedstockprocessor configured to establish a temperature from 1,640 degreesFahrenheit to 1,850 degrees Fahrenheit.

In one embodiment, the invention may include carousel platforms that mayeven simply rotate about a horizontal axis. Thus, the system may involvemechanically propelling a carbonaceous materials pyrolysis carousel, andeven mechanically propelling a pyrolytically decomposed carbonaceousmaterials processor carousel. By configuring the carousels or carouselplatforms at different levels, the system may include a tiered carousel(204). That tiered carousel (204), may involve carousel tiered platformsas shown. It may also involve coaxial and perhaps even vertical tiering.Thus there may be a coaxial carousel tiered drive system that acts tomechanically propel a tiered carousel and shown.

An important part of sequentially processing material can includetransferring the material between different environments. This can occurthrough a process transfer that moves processed material betweendifferent environments. In the embodiment shown, this process transfercan include one or more fixed decomposed carbonaceous materials scrapers(206), as well as one or more dispersionary freefall transfers (205). Bythe dispersionary freefall transfer (205) material may gravimetricallyfall from one level to the next. This can promote mixing and morecomplete processing. Thus, as carousel platforms rotate, the material onthe platforms may be subjected to fixed element scraping, which can pushthe material off of the platform and cause it to fall onto the nextprocessing platform.

In each of the reactor sections, it should be understood that additionalplatforms can be provided. For example, there can be a plurality ofinterstitial output coordinated platforms. More than one platform can beused in the pyrolysis processes such as so that the material isadequately decomposed or the like. Both the pyrolysis and reformationfunctions can have multiple platforms. For instance, as shown it can beunderstood that the system may include first and second pyrolysisenvironment process platforms, as well as first and second carbonaceousreformation environment process platforms. Each of these may includedifferentiated status such as differentiated pyrolytically decomposing,as well as differentiated reformation steps.

As can be understood from the figures, the “pod” concept can permit manyadvantages. As shown in FIGS. 18 and 21 and discussed later, systems maybe portable. In addition, environmental safety can be promoted byentirely encasing aspects of the system. Thus, by substantiallysealingly wholly containing the reactor or the like, a more safe systemcan be provided. As shown, the sealed refractory shroud (213) may beconfigured to circumscribe and create a substantially sealed processchamber and a sealed burner chamber (241). Thus there can be asubstantially wholly contained gasifier. This encasement may havethermal advantages and may be a substantially sealed circumscribing heatshield encasement that thermally encases aspects of the system. Thesealed refractory shroud (213) and other components may create a thermalcircumscribing heat shield encasement. This may surround the chamber,the platforms, the reactors, and the like. Operations performs may eveninclude: sealably encased mechanically propelling, sealably encasedpyrolytically decomposing, sealably encased carbonaceous reforming,encased processing, encased generating, encased recycling, and evengenerating a flue gas within an encased gasifier system, as but a few.

FIG. 22 shows a lower portion of a “pod” embodiment of the presentinvention. This may include a product synthesis gas combustion bottomburner (241) so that he increasing temperature is provided at a bottomlocation. This may aid in effecting a tiered heat distribution, wherethere is increasing temperature at lower levels. This can work inconjunction with the fact that processed material sequentially fallsfrom one carousel to another and thus is sequentially treated toincreasing temperatures.

In encased designs such as the “pod” system shown, the substantiallysealed circumscribing heat shield encasement may have a variety ofinputs and outputs (242). Among others, these may include arecirculatory water input (243) and a recirculatory water output (244)such as from and external, unencased, or perhaps even separate treatmentsystem that operates for treating water, gas, material or the like.These systems may even be recirculatory and thus the system may operatefor inputting recirculatory water and outputting recirculatory waterfrom an encased environment. The outputs can be varied and may include:a negatively electrostatically enhanced water species processed selectproduct gas output, a flue gas processed select product gas output, avaried retention time processed select product gas output, a selectproduct gas processed in at least a preliminary reformation coil and asecondary reformation coil output, a select product gas processed with arecycled incompletely pyrolytically decomposed carbonaceous materialoutput, and a select product gas processed with a recycled incompletelyreformed carbonaceous material output, among others.

The input can also have ferried configurations. As shown, one type ofinput can include a pneumatic propellant system (245). This could useflue gas and be a flue gas propellant system, synthesis gas and be aproduct synthesis gas propellant system. As such either flue gas orsynthesis gas might be used for propelling materials such as feedstocksolids into the reactor environments. Thus the system may have apneumatically propelled feedstock solids carbonaceous material inputthat may even pneumatically propel solids up into an areas such as thefeed plenum. By pneumatically propelling the feedstock, the input mayact as a dispersionary feedstock solids carbonaceous material input(237) that disperses a feedstock. It may also subject it to a gas, suchas for oxygen depletion, pre-heating, or the like.

As shown by running the materials up an incline, the system may includean accretive feedstock energy system (245) through which the system mayoperate for feedstock energy accretively propelling of the feedstock.Thus the feedstock has higher energy (potential or kinetic) after input.This system may also be an accretive feedstock potential energy inputsystem (248) that causes an increase in the potential energy so that thefeedstock can fall down from one platform to another by gravity withoutneeding additional energy or drive mechanisms. The embodiment showninvolves an inclined feedstock solids carbonaceous material input (249)that drives the feedstock solids carbonaceous material up an incline.This incline may even be vertical if desired such as for space savingreasons or the like.

In the embodiment shown, the input is shown as a coaxial feed system(250). This type of the system can operate for coaxially feeding andcoaxially propelling a feedstock in one path and something else in aperhaps surrounding path. In one embodiment in this may involve outercoaxially feeding a flue gas and inner coaxially feeding a feedstocksolids. These may even be established in opposite coaxial flows so thatone flows up and the other down, or one flows left and the other right.As shown there may be an inner feedstock pathway and an outer flue gaspathway. These two opposite flow direction pathways may serve to putfeedstock in and to exit flue gas or the like. While at the same timepre-heating the material and providing a feedstock coaxial pre-heatersystem (250) that may precondition it for ultimate processing. In orderto permit the pressure differential required from a feedstock, due tothe higher pressure processing reactor, the system may include one ormore continuous feed, pressure differential venturi injectors.

As mentioned earlier, it may be advantageous to utilize water, andperhaps even negative electrostatically enhanced water for processing.This may be through use of a recirculatory negatively electrostaticallyenhanced water species treatment system (259). There may be one or morenegatively electrostatically enhanced water species injectors perhapspositioned adjacent at least one of the platforms so that the water orsteam can appear in the process at the desired location. These injectorsmay even be sidewall negative electrostatically enhanced water speciesinjectors (253) that are positioned along the sidewall such as that onecarousel location. This sidewall may be an inner or outer sidewall.There may even be one or more driveshaft negative electrostaticallyenhanced water species injectors (254) that act to disburse water orsteam from in the vicinity of the driveshaft. This can aid in providingsteam at the inner and outer locations of the carousel environment. Asshown in FIG. 11, the entire water treatment process can be accomplishedexternal to the encased area. There may even be at a trailer adjacentrecirculatory negatively electrostatically enhanced water speciestreatment system (259) that would transport FIG. 11 water treatmentsystem. It should be understood that although this is shown as attachedon one trailer, such a system can be entirely separate and perhaps evenon a separate trailer or otherwise. As such an embodiment could presenta separately portable recirculatory negatively electrostaticallyenhanced water species treatment system. There could also be an adjacenttreatment system such as shown in FIG. 19 where the water treatmentcomponents are adjacent the processor and may be on one or either side.

As may be appreciated, it may be desirable to make a portable or atleast movable system. This could be configured such as on a trailer base(258). In order to permit transportation of the largest possible system,designed include a disabling collapse element (255). Such an elementcould fold-down, detach, or separate elements or components to permittransporting the entire system. Embodiments may permit compactlytransportive collapsing parts of the system and perhaps evencollectively moving a substantial portion of the gasifier system. Oncemoved the collapsed portions may be reassembled thus re-establishing thesystem in an operative state. Various portions can be made collapsible.These could include: a repositionable carbonaceous feedstock input, adetachable carbonaceous feedstock input, a separable carbonaceousfeedstock input, a collapsible inclined carbonaceous feedstock input, acollapsible inclined carbonaceous feedstock input, a collapsible feedplenum, and the like. As shown, one aspect that can facilitate ascompacted design is possible, may include having an off center feedstocksolids carbonaceous material input (256). Collapsing the system caninclude collapsing at least a potion of a recirculatory water system.This may occur by repositioning at least one water tank, by detaching atleast a portion of a recirculatory system, by separating, collapsing, orotherwise reducing in size aspects of the water system.

Of course, it may be desirable to transport the system. This may occuron a trailer or perhaps even on a low center section trailer (258). Thusas shown, the processor may be positioned at least partially in a lowcenter section of a trailer base. The entire system could be on one ormore trailers. As shown a particularly compact system is configured tobe put entirely on a single road transportable trailer. Thus anextremity of system on the trailer base may be collapsed to reduce atleast one operable condition external dimension for transport. In thismanner the system may be sized from both the perspectives of providing alarge or a small system. These designs can be configured to be sized forprocess rates such as: at least about 25 tons per day, at least about 50tons per day, at least about 100 tons per day, at least about 150 tonsper day, at least about 200 tons per day, and at least about 250 tonsper day up to about 500 tons per day.

As may be easily understood from the foregoing, the basic concepts ofthe present inventive technology may be embodied in a variety of ways.It may involve both select product gas generation techniques as well asdevices to accomplish the appropriate select product gas generation. Inthis application, the select product gas generation techniques aredisclosed as part of the results shown to be achieved by the variousdevices described and as steps which are inherent to utilization. Theyare simply the natural result of utilizing the devices as intended anddescribed. In addition, while some devices are disclosed, it should beunderstood that these not only accomplish certain methods but also canbe varied in a number of ways. Importantly, as to all of the foregoing,all of these facets should be understood to be encompassed by thisdisclosure.

The discussion included in this patent application is intended to serveas a basic description. The reader should be aware that the specificdiscussion may not explicitly describe all embodiments possible; manyalternatives are implicit. It also may not fully explain the genericnature of the invention and may not explicitly show how each feature orelement can actually be representative of a broader function or of agreat variety of alternative or equivalent elements. Again, these areimplicitly included in this disclosure. Where the invention is describedin device-oriented terminology, each element of the device implicitlyperforms a function. Apparatus claims may not only be included for thedevice described, but also method or process claims may be included toaddress the functions the invention and each element performs. Neitherthe description nor the terminology is intended to limit the scope ofthe claims that will be included in any subsequent patent application.

It should also be understood that a variety of changes may be madewithout departing from the essence of the inventive technology. Suchchanges are also implicitly included in the description. They still fallwithin the scope of this inventive technology. A broad disclosureencompassing both the explicit embodiment(s) shown, the great variety ofimplicit alternative embodiments, and the broad methods or processes andthe like are encompassed by this disclosure and may be relied upon whendrafting the claims for any subsequent patent application. It should beunderstood that such language changes and broader or more detailedclaiming may be accomplished at a later date (such as by any requireddeadline) or in the event the applicant subsequently seeks a patentfiling based on this filing. With this understanding, the reader shouldbe aware that this disclosure is to be understood to support anysubsequently filed patent application that may seek examination of asbroad a base of claims as deemed within the applicant's right and may bedesigned to yield a patent covering numerous aspects of the inventionboth independently and as an overall system.

Further, each of the various elements of the inventive technology andclaims may also be achieved in a variety of manners. Additionally, whenused or implied, an element is to be understood as encompassingindividual as well as plural structures that may or may not bephysically connected. This disclosure should be understood to encompasseach such variation, be it a variation of an embodiment of any apparatusembodiment, a method or process embodiment, or even merely a variationof any element of these. Particularly, it should be understood that asthe disclosure relates to elements of the inventive technology, thewords for each element may be expressed by equivalent apparatus terms ormethod terms—even if only the function or result is the same. Suchequivalent, broader, or even more generic terms should be considered tobe encompassed in the description of each element or action. Such termscan be substituted where desired to make explicit the implicitly broadcoverage to which this inventive technology is entitled. As but oneexample, it should be understood that all actions may be expressed as ameans for taking that action or as an element which causes that action.Similarly, each physical element disclosed should be understood toencompass a disclosure of the action which that physical elementfacilitates. Regarding this last aspect, as but one example, thedisclosure of a “filter” should be understood to encompass disclosure ofthe act of “filtering”—whether explicitly discussed or not—and,conversely, were there effectively disclosure of the act of “filtering”,such a disclosure should be understood to encompass disclosure of a“filter” and even a “means for filtering”. Such changes and alternativeterms are to be understood to be explicitly included in the description.

Any patents, publications, or other references mentioned in thisapplication for patent are hereby incorporated by reference. Anypriority case(s) claimed by this application is hereby appended andhereby incorporated by reference. In addition, as to each term used itshould be understood that unless its utilization in this application isinconsistent with a broadly supporting interpretation, common dictionarydefinitions should be understood as incorporated for each term and alldefinitions, alternative terms, and synonyms such as contained in theRandom House Webster's Unabridged Dictionary, second edition are herebyincorporated by reference. Finally, all references listed in thefollowing are hereby appended and hereby incorporated by reference,however, as to each of the above, to the extent that such information orstatements incorporated by reference might be considered inconsistentwith the patenting of this/these inventive technology such statementsare expressly not to be considered as made by the applicant(s).

I. U.S. Patent Documents

DOCUMENT NO. & PUB'N DATE PATENTEE OR KIND CODE (if known) mm-dd-yyyyAPPLICANT NAME 6,997,965 B2 02-14-2006 Katayama 6,997,118 B2 02-14-2006Chandran et al. 6,863,878 03-08-2005 Klepper 6,960,234 B2 11-01-2005Hassett 6,740,245 B2 05-25-2004 Johnson 6,790,383 B2 09-14-2004 Kim6,808,543 B2 10-26-2004 Paisley 5,792,369 08-11-1998 Johnson 4,764,18408-16-1988 Meyer 5,597,479 01-28-1997 Johnson 5,616,250 04-01-1997Johnson et al. 5,622,622 04-22-1997 Johnson 5,635,059 06-03-1997 Johnson5,685,994 11-11-1997 Johnson 5,443,719 08-22-1995 Johnson et al.

II. Nonpatent Literature

“Coal Energy Systems;” Penn State Energy Institute; BRUCE G. MILLER;Elsevier Academic Press, Boston, US, 2005 “Combustion and Gasificationof Coal;” Department of Fuel & Energy;University of Leeds, UK; A.WILLIAMS, M. POURKASHANIAN, J. M. JONES; Taylor &Francis, NY, US, 2000“Singlet Molecular Oxygen;” Wayne State University; A. PAUL SCHAAP;Dowden, Hutchinson & Ross, Inc.;PA, US, 1976 “Biomass GasificationOverview;’ White Paper, National Renewable Energy Laboratory; Golden,CO; RICHARD L. BAIN; January 2004 “Superoxide Chemistry;” McGraw-HillEncyclopedia Science & Technology;7^(th) Edition; pages 667-668 UnitedStates Provisional Patent Application Number 60/791,401, filed Apr. 11,2006, Entitled: Select synthesis gas generation apparatus and method

Thus, the applicant(s) should be understood to have support to claim andmake a statement of invention to at least: i) each of the processdevices as herein disclosed and described, ii) the related methodsdisclosed and described, iii) similar, equivalent, and even implicitvariations of each of these devices and methods, iv) those alternativedesigns which accomplish each of the functions shown as are disclosedand described, v) those alternative designs and methods which accomplisheach of the functions shown as are implicit to accomplish that which isdisclosed and described, yl) each feature, component, and step shown asseparate and independent inventions, vii) the applications enhanced bythe various systems or components disclosed, viii) the resultingproducts produced by such systems or components, ix) each system,method, and element shown or described as now applied to any specificfield or devices mentioned, x) methods and apparatuses substantially asdescribed hereinbefore and with reference to any of the accompanyingexamples, xi) the various combinations and permutations of each of theelements disclosed, xii) each potentially dependent claim or concept asa dependency on each and every one of the independent claims or conceptspresented, and xiii) all inventions described herein.

With regard to claims whether now or later presented for examination, itshould be understood that for practical reasons and so as to avoid greatexpansion of the examination burden, the applicant may at any timepresent only initial claims or perhaps only initial claims with onlyinitial dependencies. Support should be understood to exist to thedegree required under new matter laws—including but not limited toEuropean Patent Convention Article 123(2) and United States Patent Law35 USC 132 or other such laws—to permit the addition of any of thevarious dependencies or other elements presented under one independentclaim or concept as dependencies or elements under any other independentclaim or concept. In drafting any claims at any time whether in thisapplication or in any subsequent application, it should also beunderstood that the applicant has intended to capture as full and broada scope of coverage as legally available. To the extent thatinsubstantial substitutes are made, to the extent that the applicant didnot in fact draft any claim so as to literally encompass any particularembodiment, and to the extent otherwise applicable, the applicant shouldnot be understood to have in any way intended to or actuallyrelinquished such coverage as the applicant simply may not have beenable to anticipate all eventualities; one skilled in the art, should notbe reasonably expected to have drafted a claim that would have literallyencompassed such alternative embodiments.

Further, if or when used, the use of the transitional phrase“comprising” is used to maintain the “open-end” claims herein, accordingto traditional claim interpretation. Thus, unless the context requiresotherwise, it should be understood that the term “comprise” orvariations such as “comprises” or “comprising”, are intended to implythe inclusion of a stated element or step or group of elements or stepsbut not the exclusion of any other element or step or group of elementsor steps. Such terms should be interpreted in their most expansive formso as to afford the applicant the broadest coverage legally permissible.

Finally, any claims set forth at any time are hereby incorporated byreference as part of this description of the inventive technology, andthe applicant expressly reserves the right to use all of or a portion ofsuch incorporated content of such claims as additional description tosupport any of or all of the claims or any element or component thereof,and the applicant further expressly reserves the right to move anyportion of or all of the incorporated content of such claims or anyelement or component thereof from the description into the claims orvice-versa as necessary to define the matter for which protection issought by this application or by any subsequent continuation, division,or continuation-in-part application thereof, or to obtain any benefitof, reduction in fees pursuant to, or to comply with the patent laws,rules, or regulations of any country or treaty, and such contentincorporated by reference shall survive during the entire pendency ofthis application including any subsequent continuation, division, orcontinuation-in-part application thereof or any reissue or extensionthereon.

1-123. (canceled)
 124. A method for select synthesis gas generation fromsolid carbonaceous materials comprising the steps of: inputting afeedstock solids carbonaceous material; subjecting said feedstock solidscarbonaceous material to a pressurized environment; increasing antemperature within said pressurized environment to which said feedstocksolids carbonaceous material is subjected; engaging said feedstocksolids carbonaceous material with a plurality of movement guides;transporting said feedstock solids carbonaceous material in atemperature varied environment as a result of said movement guides;moving said feedstock solids carbonaceous material through aliquefaction zone of said temperature varied environment as a result ofsaid transporting; pyrolytically decomposing at least a portion of saidfeedstock solids carbonaceous material in a solid carbonaceous materialsgasifier system; creating a pyrolytically decomposed carbonaceousmaterial; processing said pyrolytically decomposed carbonaceous materialin said solid carbonaceous materials gasifier system to generate atleast some components of a select product gas; outputting at least someselect product gas from said solid carbonaceous materials gasifiersystem in response to said step of processing; cycling said movementguides throughout a varied temperature regime; automaticallyperiodically clearing said movement guides as a result of said step ofcycling said movement guides throughout a varied temperature regime.125. A method for select synthesis gas generation from solidcarbonaceous materials as described in claim 124 wherein said step ofengaging said feedstock solids carbonaceous material comprises the stepof engaging said feedstock solids carbonaceous material with a pluralityof translatable movement guides.
 126. A method for select synthesis gasgeneration from solid carbonaceous materials as described in claim 125wherein said step of engaging said feedstock solids carbonaceousmaterial with a plurality of translatable movement guides comprises thestep of engaging said feedstock solids carbonaceous material with atrack feeder.
 127. A method for select synthesis gas generation fromsolid carbonaceous materials as described in claim 126 furthercomprising the step of maximizing a surface area of said track feeder.128. A method for select synthesis gas generation from solidcarbonaceous materials as described in claim 127 wherein said step ofmaximizing comprises the step of dimensioning said track feeder selectedfrom the group consisting of: dimensioning to at least 24 inches inwidth, dimensioning to at least 30 inches in width, dimensioning to atleast 36 inches in width, dimensioning to at least 42 inches in width,dimensioning to at least 48 inches in width, dimensioning to at least 54inches in width, dimensioning to at least 60 inches in width,dimensioning to at least 66 inches in width, dimensioning to at least 72inches in width, dimensioning to at least 3 feet in length, dimensioningto at least 6 feet in length, dimensioning to at least 9 feet in length,dimensioning to at least 12 feet in length, dimensioning to at least 15feet in length, dimensioning to at least 18 feet in length, anddimensioning to at least 21 feet in length.
 129. A method for selectsynthesis gas generation from solid carbonaceous materials as describedin claim 124 further comprising the step of varying a retention time ofsaid feedstock solids carbonaceous material within said temperaturevaried environment.
 130. A method for select synthesis gas generationfrom solid carbonaceous materials as described in claim 129 wherein saidstep of varying a retention time comprises the step of dominativelypyrolytically decomposing said feedstock solids carbonaceous material.131. A method for select synthesis gas generation from solidcarbonaceous materials as described in claim 129 wherein said step ofvarying a retention time comprises the step of varying a speed selectedfrom the group consisting of: varying a speed of said plurality ofmovement guides, varying a speed of said plurality of translatablemovement guides, and varying a speed of said track feeder.
 132. A methodfor select synthesis gas generation from solid carbonaceous materials asdescribed in claim 129 wherein said step of varying a retention timecomprises the step of retaining said feedstock solids carbonaceousmaterial selected from the group consisting of: retaining for at least 2minutes, retaining for at least 3 minutes, retaining for at least 4minutes, retaining for at least 5 minutes, retaining for at least 6minutes, retaining for at least 7 minutes, retaining for at least 8minutes, retaining for at least 9 minutes, retaining for at least 10minutes, retaining for at least 11 minutes, retaining for at least 12minutes, retaining for at least 13 minutes, retaining for at least 14minutes, retaining for at least 15 minutes, retaining for at least 16minutes, retaining for at least 17 minutes, retaining for at least 18minutes, retaining for at least 19 minutes, and retaining for at least20 minutes.
 133. A method for select synthesis gas generation from solidcarbonaceous materials as described in claim 124 wherein said step oftransporting said feedstock solids carbonaceous material comprises thestep of transporting said feedstock solids carbonaceous material in apyrolysis chamber of said temperature varied environment.
 134. A methodfor select synthesis gas generation from solid carbonaceous materials asdescribed in claim 133 wherein said step of transporting said feedstocksolids carbonaceous material comprises the step of transporting saidfeedstock solids carbonaceous material through a temperature gradientfrom about 300 degrees Fahrenheit to about 1000 degrees Fahrenheit. 135.A method for select synthesis gas generation from solid carbonaceousmaterials as described in claim 134 wherein said step of transportingsaid feedstock solids carbonaceous material comprises the step oftransporting said feedstock solids carbonaceous material at a pressurebetween 50 psi and 100 psi.
 136. A method for select synthesis gasgeneration from solid carbonaceous materials as described in claim 124further comprising the step of liquefying at least some of saidfeedstock solids carbonaceous material.
 137. A method for selectsynthesis gas generation from solid carbonaceous materials as describedin claim 124 wherein said step of cycling said movement guides comprisesthe step of continuously varying the temperature of said movementguides.
 138. A method for select synthesis gas generation from solidcarbonaceous materials as described in claim 137 wherein said step ofcontinuously varying the temperature of said movement guides comprisesthe step of avoiding holding said movement guides at a liquefactiontemperature.
 139. A method for select synthesis gas generation fromsolid carbonaceous materials as described in claim 137 wherein said stepof continuously varying the temperature of said movement guidescomprises a step selected from the group consisting of: cyclicallyraising and lowering the temperature of said movement guides andcyclically liquefying and vaporizing at least some of said feedstocksolids carbonaceous material transported by said movement guides.
 140. Amethod for select synthesis gas generation from solid carbonaceousmaterials as described in claim 137 wherein said step of continuouslyvarying the temperature of said movement guides comprises the step ofavoiding binding the motion of said movement guides.
 141. A method forselect synthesis gas generation from solid carbonaceous materials asdescribed in claim 124 wherein said step of cycling said movement guidescomprises the step of moving a track feeder through said variedtemperature regime.
 142. A method for select synthesis gas generationfrom solid carbonaceous materials as described in claim 124 wherein saidstep of automatically periodically clearing said movement guidescomprises the step of vaporizing at least some liquefied said feedstocksolids carbonaceous material transported by said movement guides.
 143. Amethod for select synthesis gas generation from solid carbonaceousmaterials as described in claim 142 wherein said step of vaporizing atleast some liquefied said feedstock solids carbonaceous materialcomprises the step of transporting said liquefied feedstock solidscarbonaceous material from a liquefaction zone to a post-liquefactiontemperature zone within said temperature varied environment.
 144. Amethod for select synthesis gas generation from solid carbonaceousmaterials as described in claim 143 further comprising the step ofreceiving at least some said feedstock solids carbonaceous materialwithin a pre-liquefaction temperature zone of said temperature variedenvironment.
 145. A method for select synthesis gas generation fromsolid carbonaceous materials as described in claim 124 furthercomprising the step of adding a negatively electrostatically enhancedwater species to said feedstock solids carbonaceous material within saidtemperature varied environment.
 146. A method for select synthesis gasgeneration from solid carbonaceous materials as described in claim 145wherein said step of adding a negatively electrostatically enhancedwater species comprises the step of adding negatively electrostaticallyenhanced steam to said feedstock solids carbonaceous material withinsaid temperature varied environment.
 147. A method for select synthesisgas generation from solid carbonaceous materials as described in claim124 further comprising the step of adding a flue gas to said feedstocksolids carbonaceous material within said temperature varied environmentselected from the group consisting of: adding a flue gas, adding apressurized flue gas, adding a flue gas pressurized to at least 80 psi,and adding a flue gas moving at least 75-100 cfm.
 148. A method forselect synthesis gas generation from solid carbonaceous materials asdescribed in claim 147 wherein said step of adding a flue gas comprisesthe step of affecting a temperature within said temperature variedenvironment.
 149. A method for select synthesis gas generation fromsolid carbonaceous materials as described in claim 147 wherein said stepof adding a flue gas comprises the step of providing motive forcepressurization.
 150. A method for select synthesis gas generation fromsolid carbonaceous materials as described in claim 124 furthercomprising the step of adding a substance to said feedstock solidscarbonaceous material within said temperature varied environmentselected from the group consisting of: adding a scrubber recycled tar,adding a scrubber recycled phenol, adding a scrubber recycled sulfur,adding scrubber recycled carbon dioxide, and adding a scrubber recycledsolid.
 151. A method for select synthesis gas generation from solidcarbonaceous materials as described in claim 124 further comprising thestep of adding select product gas to said feedstock solids carbonaceousmaterial within said temperature varied environment selected from thegroup consisting of: adding select product gas, adding wet selectproduct gas, adding dry select product gas, and adding recycled selectproduct gas.
 152. A method for select synthesis gas generation fromsolid carbonaceous materials as described in claim 151 wherein said stepadding select product gas to said feedstock solids carbonaceous materialwithin said temperature varied environment comprises a step selectedfrom the group consisting of: raising a temperature of said temperaturevaried environment and providing motive force pressurization of saidtemperature varied environment.
 153. A method for select synthesis gasgeneration from solid carbonaceous materials as described in claim 124wherein said step of transporting said feedstock solids carbonaceousmaterial comprises the step of transporting between about 50 tons and500 tons of said feedstock solids carbonaceous material per day.154-363. (canceled)
 364. A solid carbonaceous materials select synthesisgas generation apparatus comprising: a feedstock solids carbonaceousmaterials input; a gasifier process flow path originating at saidfeedstock solids carbonaceous materials input and routed through saidsolid carbonaceous materials gasifier system; at least one pressuresystem joined to at least a portion of said gasifier process flow path;a variable temperature zone heater system joined to at least a portionof said gasifier process flow path; a temperature varied environmentresponsive to said variable temperature zone heater system and having afeedstock solids carbonaceous materials liquefaction zone through whichsaid gasifier process flow path is routed; a plurality oftrans-liquefaction feedstock solids carbonaceous materials movementguides disposed through said temperature varied environment; atemperature varied cyclical return to which said plurality oftrans-liquefaction feedstock solids carbonaceous materials movementguides are joined; a solid carbonaceous materials pyrolysis chamber ofsaid temperature varied environment through which said gasifier processflow path is routed; a pyrolytically decomposed carbonaceous materialsprocessor through which said gasifier process flow path is routed; aselect product gas output located at a terminus of said gasifier processflow path routed through said solid carbonaceous materials gasifiersystem. 365-801. (canceled)